JP6459141B2 - Reactor - Google Patents

Description

  The present invention relates to a reactor that is used in a vehicle-mounted DC-DC converter or a component of a power converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor that has a small number of parts, can firmly fix an assembly to a case, and has excellent assembly workability.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. Patent Document 1 discloses a reactor including a coil, a magnetic core in which the coil is disposed, a case that houses a combination of the coil and the magnetic core, and a sealing resin portion that is filled in the case. ing. To fix the combination to the case, place the stay in contact with the upper surface of the outer core part that is located outside the coil of the magnetic core, and screw this stay to the stay mounting part provided in the case. Is going on. The stay presses the outer core portion toward the bottom surface of the case, and the assembly is fixed to the case.

JP 2014-107294 A

  It is desired to reduce the number of reactor parts and to improve the assembly workability of the reactor.

  When fixing the assembly to the case, using the stay of Patent Document 1, it is difficult to handle because the stay is a separate member from the assembly and the case, and it is difficult to position the stay relative to the assembly and the case.

  The present invention has been made in view of the above circumstances, and one of the objects of the present invention is to provide a reactor that has a small number of components, can be firmly fixed to a case, and has excellent assembly workability.

  A reactor according to an aspect of the present invention includes a coil having a winding portion, a magnetic core having a portion disposed in the winding portion, and a portion interposed between the winding portion and the magnetic core. An interposed member, and a bottomed container-like case that houses an assembly of the coil, the magnetic core, and the interposed member. The interposition member includes a fixing portion and a pressing portion. The fixing portion has a through hole of a fastening member, is fastened to the inner bottom surface side of the case by the fastening member, and fixes the combination to the case. The pressing portion is a member that is formed integrally with the fixed portion and is interposed between the inner core surface of the case and a region on the inner bottom surface side of the case and the magnetic core, and the case of the fixed portion The coil is pressed against the inner bottom surface of the case as it is fixed to the case.

  The reactor has a small number of parts, can firmly fix the assembly to the case, and is excellent in assembling workability.

1 is a schematic perspective view of a reactor according to a first embodiment. It is (II)-(II) sectional drawing of the reactor of FIG. 1 is a schematic exploded perspective view of a reactor according to a first embodiment. FIG. 3 is a schematic exploded perspective view of an assembly provided in the reactor according to the first embodiment. 2 is a schematic exploded perspective view of an interposition member provided in Embodiment 1. FIG.

[Description of Embodiment of the Present Invention]
First, embodiments of the present invention will be listed and described.

  (1) The reactor which concerns on embodiment of this invention is interposed between the coil which has a winding part, the magnetic core which has a part arrange | positioned in the said winding part, and the said winding part and the said magnetic core. And a bottomed container-like case that houses an assembly of the coil, the magnetic core, and the interposed member. The interposition member includes a fixing portion and a pressing portion. The fixing portion has a through hole of a fastening member, is fastened to the inner bottom surface side of the case by the fastening member, and fixes the combination to the case. The pressing portion is a member that is formed integrally with the fixed portion and is interposed between the inner core surface of the case and a region on the inner bottom surface side of the case and the magnetic core, and the case of the fixed portion The coil is pressed against the inner bottom surface of the case as it is fixed to the case.

  In the above reactor, the interposition member includes a fixing portion, so that the combined body can be fixed to the case with the constituent members of the combined body. Therefore, it is easy to arrange the combined body with respect to the case, and the assembly workability of the reactor is improved. Excellent. This is because it is possible to easily fix the assembly and the case in a positioned state simply by aligning the through-hole of the fixing portion and the attachment portion of the fastening member with respect to the case and fixing them with the fastening member. In addition, since the assembly is fixed to the case using the constituent members of the assembly, it is not necessary to prepare another member such as a conventional stay, and the number of parts can be reduced.

  Furthermore, since the above-described reactor includes the pressing portion, the pressing portion presses the coil against the bottom surface of the case as the fixing portion is fixed to the case, so that the coil and the inner bottom surface of the case Can be easily fixed in contact. The reactor is excellent in heat dissipation because the coil and the inner bottom surface of the case are in contact with each other. When the coil is pressed against the inner bottom surface of the case by the pressing part, the coil and the inner bottom surface of the case may be in direct contact with each other, or an interposition such as a heat dissipation sheet or adhesive is interposed between the coil and the inner bottom surface of the case. Indirect contact may occur.

  (2) As an example of the above reactor, the case may be a bottomed rectangular tube case, and the fixed portion may be a tongue piece extending toward each corner of the case.

  In the case of a square tube case with a bottom, by setting the fixed part of the assembly and the case to the corner that becomes the gap formed in the case, it is possible to suppress the enlargement of the case and increase the size of the reactor. Can be suppressed. Since the fixing portion has a shape extending toward the corner portion of the case, the corner portion of the outer core piece arranged outside the winding portion of the magnetic core can be covered with the fixing portion. It is easy to suppress damage to the corners.

  (3) As an example of the reactor, the fixing portion is a plate-like piece having a cantilever structure in which the through hole side is a free end and the opposite side is a connecting end with the pressing portion side, and the interposition A form with which the member is provided with the reinforcement part which suppresses rocking | fluctuation on the free end side of the said fixing | fixed part is mentioned.

  When the fixing part is a plate-like piece with a cantilever support structure with the through hole side as a free end, a fixing part is provided to suppress the swinging of the fixing part on the free end side, thereby fixing the fixing part to the case. As a result, the pressing action of the pressing portion can be made to work reliably. This is because the fixing portion and the pressing portion behave as an integral rigid body, so that the pressing force acting on the fixing portion is easily applied to the coil from the pressing portion. Therefore, the assembly can be fixed to the case while the coil and the inner bottom surface of the case are in contact with each other.

  (4) As an example of the reactor described above, the interposition member is configured by combining a pair of split interposition members that are divided in the axial direction of the winding portion, and one of the pair of split interposition members is The form provided with the cylindrical part which can contain all the inner core pieces and gap materials which are included in the said winding part among the said magnetic cores including the said pressing part is mentioned.

  According to the above configuration, since the cylindrical portion accommodates all of the inner core piece and the gap material, the inner core piece and the gap material can be easily positioned with respect to the cylindrical portion, and the positioning state is stabilized. Can be secured. Moreover, since the inner core piece and the gap material can be handled in a state of being accommodated in the cylindrical portion, the assembly workability of the reactor is excellent. Since the pressing portion is disposed over the entire length of the laminate of the inner core piece and the gap material disposed in the winding portion, that is, is disposed over the entire length in the axial direction of the coil, the coil by the pressing portion Can be stably pressed against the case.

  (5) As an example of the reactor in which the interposition member is configured by combining a pair of split interposition members, a form in which the pair of split interposition members include engaging portions that engage with each other is exemplified.

  According to the above configuration, the divided interposition members can be easily engaged with each other, and the engaged divided interposition members are not easily displaced. Therefore, the coil and the magnetic core are not easily displaced by the engagement of the divided interposition members, the assembly is easy to handle, and the assembly workability of the reactor is excellent.

[Details of the embodiment of the present invention]
Details of the embodiment of the present invention will be described below. In addition, this invention is not limited to these illustrations, is shown by the claim, and intends that all the changes within the meaning and range equivalent to a claim are included. The same code | symbol in a figure shows the same name thing.

<Embodiment 1>
With reference to FIGS. 1-5, the reactor 1 of Embodiment 1 is demonstrated.

[Reactor]
-Overall configuration As shown in FIGS. 1 and 2, the reactor 1 of the first embodiment includes a coil 2 having winding portions 2 a and 2 b formed by spirally winding a winding 2 w, and winding portions 2 a and 2 b. A magnetic core 3 having a portion disposed between the winding cores 2a and 2b, an intervening member 5 having a portion interposed between the magnetic core 3 and the coil 2, the magnetic core 3 and the interposing member 5. And a case 4 for housing the combined body 10. Here, the reactor 1 includes a sealing resin portion 6 that is filled in the case 4 and seals the combined body 10. The reactor 1 according to the first embodiment is characterized in that the combined body 10 can be fixed to the case 4 in a state where the coil 2 is in contact with the inner bottom surface of the case 4 (the inner surface of the bottom plate portion 40) by the interposed member 5. . Hereinafter, each component will be described in detail. In the following description, the installation side (the bottom plate 40 side of the case 4) when the assembly 10 is installed in the case 4 is the lower side, and the opposite side (the opening side of the case 4) is the upper side.

-Coil As shown in FIG. 4, the coil 2 includes a pair of cylindrical winding portions 2a and 2b formed by spirally winding one continuous winding 2w, and both winding portions 2a, A connecting portion 2r for connecting 2b. Each winding part 2a, 2b is formed in a hollow cylinder shape with the same number of turns and the same winding direction, and is arranged in parallel (side by side) so that the respective axial directions are parallel. The connecting portion 2r is a portion bent in a U shape that connects the winding portions 2a and 2b. The coil 2 may be formed by spirally winding a single winding without a joint. Alternatively, the windings 2a and 2b may be formed by separate windings, and the windings 2a and 2b You may form by joining the edge parts of a coil | winding by welding or crimping | compression-bonding. Both end portions of the coil 2 are extended from the winding portions 2a and 2b in an appropriate direction and connected to a terminal member (not shown). An external device such as a power source for supplying power is connected to the coil 2 through the terminal member.

  Each winding part 2a, 2b of this embodiment is formed in the shape of a square tube. The rectangular cylindrical winding parts 2a and 2b are winding parts having rounded corners whose end face shape is a quadrangle (including a square shape). Of course, the winding portions 2a and 2b may be formed in a cylindrical shape. The cylindrical winding portion is a winding portion whose end face shape is a closed curved surface shape (an elliptical shape, a perfect circle shape, a race track shape, etc.).

  The coil 2 including the winding portions 2a and 2b is a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor such as a flat wire or a round wire made of a conductive material such as copper, aluminum, magnesium, or an alloy thereof. Can be configured. In the present embodiment, the winding portions 2a and 2b are formed by edgewise winding a rectangular wire made of copper and a conductor made of enamel (typically polyamideimide). Yes.

Magnetic core 3 includes a plurality of columnar inner core pieces 31m,..., A pair of U-shaped outer core pieces 32m and 32m, and a plurality of magnetic cores 3 interposed between the core pieces, as shown in FIG. The gap members 31g, ... are provided. The inner core pieces 31m,... Are magnetic pieces that are entirely disposed within the winding portions 2a, 2b, and the outer core pieces 32m, 32m are magnetic pieces having portions that are disposed outside the winding portions 2a, 2b. That is. The outer core pieces 32m and 32m may have a portion partially disposed in the winding portions 2a and 2b. In this example, the outer core pieces 32 and 32m are outside the winding portions 2a and 2b. And a portion disposed in the winding portions 2a and 2b. The outer core pieces 32m, 32m are arranged so that the U-shaped openings face each other, and a laminate of the inner core pieces 31m,... And the gap material 31g, is arranged side by side (in parallel) between the outer core pieces 32m, 32m. Be placed. With this arrangement, the magnetic core 3 is assembled in an annular shape, and forms a closed magnetic path when the coil 2 is excited.

.. Inner core piece The inner core piece 31m preferably has a shape that matches the shape of the winding portions 2a and 2b. Here, as shown in FIG. 4, the shape of the inner core piece 31m is a rectangular parallelepiped shape, and the corners thereof are rounded along the corners of the inner peripheral surfaces of the winding portions 2a and 2b. The number of inner core pieces 31m can be selected as appropriate.

.. Outer core piece The pair of outer core pieces 32m, 32m have the same shape and are substantially U-shaped when viewed from above in FIG. The outer core piece 32m is a rectangular parallelepiped outer core base 321 disposed outside the winding portions 2a and 2b and straddling between the winding portions 2a and 2b, and is wound around the outer core base 321. A pair of protrusions 322 disposed in the portions 2a and 2b, respectively. The outer core base portion 321 and the pair of projecting portions 322 and 322 are integrally formed. Further, here, the outer core base 321 is integrally formed with a portion protruding to the opposite side of the pair of protruding portions 322 and 322. The cross-sectional area of the protruding portion is substantially the same as the cross-sectional area of the inner core piece 31m and the protruding portion 322. The end surfaces of the pair of projecting portions 322 and 322 have substantially the same shape and size as the end surface of the inner core piece 31m, and the size and projecting length have a predetermined magnetic path cross-sectional area corresponding to the coil 2. Can be selected as appropriate. The pair of protrusions 322 and 322 preferably have a shape that matches the shape of the winding portions 2a and 2b. Here, the corners are substantially at the corners of the inner peripheral surfaces of the winding portions 2a and 2b. Rounded along.

  The lower surface of the outer core base 321 in the U-shaped outer core pieces 32m, 32m protrudes from the lower surface of the inner core piece 31m. When the coil 2 and the magnetic core 3 are assembled, the lower surface of the outer core base 321 is It is flush with the lower surface of the coil 2. That is, the installation surface of the combined body 10 is configured by one surface (lower surface) of the coil 2 and one surface of the outer core piece 32m of the magnetic core 3 (lower surface of the outer core base portion 321). Therefore, the reactor 1 is configured such that the combined body 10 is stably disposed on the bottom plate portion 40 of the case 4, and a part of the magnetic core 3 is also in contact with the bottom plate portion 40 of the case 4 in addition to the coil 2. Increases sex.

  In this example, both the inner core piece 31m and the outer core piece 32m are compacted bodies. The green compact is typically a raw material powder containing a soft magnetic metal powder such as iron or an iron alloy (Fe-Si alloy, Fe-Ni alloy, etc.) and a binder (resin etc.) or a lubricant as appropriate. After being molded, it is obtained by performing a heat treatment for the purpose of removing distortion associated with the molding. By using, as a raw material powder, a coating powder obtained by subjecting a metal powder to insulation treatment, or a mixed powder obtained by mixing a metal powder and an insulating material, the metal powder and the insulating material interposed between the metal particles after forming are substantially used. A compacted green body is obtained. Since this compacting body contains an insulating material, eddy current can be reduced and the loss is low.

.. Gap material The gap material 31g is made of a material having a lower relative permeability than the core pieces 31m and 32m, typically a non-magnetic material such as alumina. In this example, the gap material 31g is a non-magnetic material flat plate having a rectangular shape in plan view. The shape and number of the gap material 31g can be selected as appropriate. The gap material 31g interposed between the core pieces 31m and 32m can be used as an air gap instead of the gap material 31g or in combination with the gap material 31g.

Interposing member The interposing member 5 is a member that is interposed between the coil 2 (winding portions 2 a and 2 b) and the magnetic core 3 and insulates the coil 2 from the magnetic core 3. As shown in FIGS. 4 and 5, the interposed member 5 includes a pair of divided interposed members 5 </ b> A and 5 </ b> B that are divided into two in the axial direction of the coil 2 (winding portions 2 a and 2 b). When the interposition member 5 is combined with the pair of split interposition members 5A and 5B, the interposition member 51 is disposed between the winding portions 2a and 2b, and between the winding portions 2a and 2b and the outer core piece 32m. An interposing end face interposition part 52 and an extension part 53 extending outward in the axial direction of the winding parts 2a and 2b and arranged on the upper surface of the outer core piece 32m are provided. Here, in the split interposition member 5A, the inner interposition part 51, the end face interposition part 52, and the extension part 53 are integrally formed, and in the split interposition member 5B, the end face interposition part 52 and the extension part 53 are integrally formed. It is molded into.

  The inner interposed portion 51 has a pressing portion 51p interposed between the magnetic core 3 and the region on the bottom plate portion 40 side of the case 4 on the inner bottom surface of the winding portions 2a and 2b. The extending portion 53 includes a fixing portion 53 f that fixes the combined body 10 to the case 4. The reactor 1 of the first embodiment is characterized in that the pressing portion 51p presses the coil 2 against the bottom plate portion 40 side of the case 4 as the fixing portion 53f is fixed to the case 4.

..Inner intervention part (fixed part)
The inner interposition part 51 is a cylindrical part that can accommodate a laminate of the inner core pieces 31m,... And the gap material 31g,. Here, the inner interposition part 51 is composed of four curved interposition pieces 51f so as to correspond to the four corners of the laminate. Each interposed piece 51f is curved so as to follow each corner of the laminate, so that the laminate can be easily stored in the inner interposed portion 51. The inner interposition part 51 has a cylindrical cross section formed by the four interposition pieces 51f,... Along the outer shape of the inner core piece 31m. Each interposition piece 51f is formed to have a frame shape connected at one end on the end surface interposition part 52 side. That is, the inner interposition part 51 is formed with a slit in which one end side in the axial direction of the tubular part is opened and the other end side (end face interposition part 52 side) is closed on the side surface of the tubular part. Since the inner interposition part 51 is formed with a slit, it can be inserted into the inner interposition part 51 from the opening side of the slit in a state where each inner core piece 31m,... And the gap material 31g,. Easy to work.

  Among the inner intervening portions 51, an intervening piece 51f interposed between a region on the bottom plate portion 40 side of the case 4 on the inner bottom surface of the winding portions 2a and 2b and the magnetic core 3 is a case 4 formed by a fixing portion 53f described later. This is a pressing portion 51p that plays a role of pressing the coil 2 against the bottom plate portion 40 side of the case 4 as it is fixed to (see FIGS. 2 and 5). The relationship between the fixing portion 53f and the pressing portion 51p will be described in the reactor manufacturing method described later.

  An engaging portion 51e that engages with an engaging portion 52e formed on the end surface interposed portion 52 of the split interposed member 5B is formed at the distal end portion of the two interposed pieces 51f disposed on the upper side of the inner interposed portion 51. Yes. By engaging the engaging portion 51e of the inner interposed portion 51 (each interposed piece 51f) of the divided interposing member 5A with the engaging portion 52e of the end surface interposed portion 52 of the divided interposing member 5B, the divided interposing members 5A and 5B are engaged. Can be integrated in a state of being positioned with respect to each other. The engagement between the two will be described later.

..End surface interposed portion The end surface interposed portion 52 is an E-shaped member having an open top surface on which the pair of projecting portions 322 and 322 of the outer core piece 32m are respectively disposed. By disposing an extension portion 53 described later in the opening portion of the E-shaped member, a B-shaped frame-like portion having two insertion holes 52h and 52h through which the protrusions 322 and 322 can be inserted is obtained. . The end surface interposition part 52 provided in the split interposition member 5A is formed by integrally forming the inner interposition part 51, the partition part 52d, and the sensor holding part 52s on the surface facing the winding parts 2a and 2b. In addition, an extending portion 53 described later is integrally formed on the surface facing the outer core piece 32m. The end surface interposed portion 52 provided in the divided interposing member 5B is integrally formed with an engaging portion 52e that engages with the divided interposing member 5A and a partition portion 52d on the surface facing the winding portions 2a and 2b. An extending portion 53 described later is integrally formed on the surface facing the outer core piece 32m.

  In this example, since the outer core pieces 32m and 32m are U-shaped, the protruding portions 322 and 322 of the outer core piece 32m are inserted into the insertion holes 52h and 52h of the end surface interposed portion 52, so that Thus, the outer core piece 32m can be easily positioned. That is, positioning of the inner core pieces 31m,... And the gap members 31g,... And the outer core pieces 32m, 32m and positioning of the magnetic core 3 and the coil 2 can be easily performed.

  The partition part 52d is provided at a position between the inner interposed parts 51 and 51 so as to protrude from the surface of the end face interposed part 52 on the coil 2 side. This partition part 52d is interposed between the winding parts 2a and 2b when the divided interposing members 5A and 5B are assembled to the winding parts 2a and 2b, and maintains the isolated state of the winding parts 2a and 2b. By this isolation, the insulation between the winding parts 2a and 2b can be ensured. This partition part 52d is provided on both of the split interposing members 5A and 5B.

  The sensor holding part 52s provided in the split interposition member 5A is provided so as to protrude from the coil 2 side surface of the end face interposition part 52 continuously from the upper end side of the partition part 52d in the axial direction of the coil 2. ing. The sensor holding part 52s places a sensor (not shown) in a space formed by the opposite corners R of the winding parts 2a and 2b, and connects the divided interposing members 5A and 5B to the winding parts 2a and 5b. When assembled to 2b, the upper side of the sensor can be covered with the sensor holding portion 52s, and the sensor can be fixed and protected. Examples of the sensor include a sensor that measures a physical quantity of the reactor 1 such as a temperature sensor or a current sensor.

  The engaging part 52e provided in the split interposing member 5B is provided so as to protrude from the surface of the end face interposing part 52 on the coil 2 side, and this protruding part (convex part) is provided in the split interposing member 5A ( It engages with a concave engaging part 51e formed in the inner interposition part 51). The engaging portion 52e is formed corresponding to the engaging portion 51e formed in the inner interposition portion 51, and for each of the insertion holes 52h, 52h, on the upper surface of the insertion hole 52h, Plate-shaped protruding pieces are formed on both side surfaces. ] -Shaped engaging portion 52e engages with an engaging portion 51e provided at the tip of two interposing pieces 51f arranged above the inner interposing portion 51 of the split interposing member 5A, and two plate-like engaging portions. The joint portion 52e engages with a slit (engagement portion 51e) formed on the side surface of the inner interposition portion 51 of the split interposition member 5A. When the divided interposing members 5A and 5B are engaged by the engaging portions 51e and 52e, the engaging portion is opened at the center portion of the lower surface in the circumferential direction, and the cross section is C-shaped. When the split interposition members 5A and 5B in which the laminate of the inner core pieces 31m, ... and the gap material 31g, ... are assembled in the winding parts 2a, 2b are assembled to the winding parts 2a, 2b, the insertion holes 52h , 52h on the lower surface side] there is no engagement portion, so an opening is formed, and this opening becomes a resin flow path. Therefore, when the assembly 10 is housed in the case 4 and the case 4 is filled with an unsolidified constituent resin of the sealing resin portion 6 to be described later, from this opening to the space between the coil 2 and the magnetic core 3. It is possible to fill the unsolidified constituent resin of the sealing resin portion 6.

..Extending part (fixed part)
The extending portion 53 is provided so as to extend to the side where the outer core piece 32m is disposed, continuously from the upper end of the end surface interposed portion 52. The extending portion 53 is a plate-like member extending in the thickness direction and the width direction of the outer core base portion 321 of the outer core piece 32m. Here, the extending portion 53 of the split interposing member 5A extends over the entire width up to about 1/3 of the maximum thickness of the outer core base portion 321, and the corner portion of the case 4 is further outward than that. It is divided into two forks. At this time, it is preferable that the portion that is divided into two and extends is symmetrical with respect to the center line in the width direction of the outer core base portion 321 of the outer core piece 32m. The extending portion 53 of the split interposing member 5B extends over the entire width up to about 2/3 of the maximum thickness of the outer core base portion 321, and outwardly toward the corner portion of the case 4. It extends into two branches. Since the connecting portion 2r of the coil 2 is disposed above the outer core base 321 on the side where the divided interposing member 5B is disposed, the extending portion 53 of the divided interposing member 5B is wider than the divided interposing member 5A. ing.

  The extending portion 53 is provided with a flat plate-like fixing portion 53f that is fastened to the bottom plate portion 40 side of the case 4 by a fastening member 9 such as a bolt (FIGS. 1 and 3) at a tip portion that is bifurcated outwardly. A through hole 53h through which the fastening member 9 passes is formed in the fixing portion 53f. The combined body 10 is fixed to the case 4 by aligning the through hole 53h with the mounting hole 45h (FIG. 3) formed in the case 4 and fixing the through hole 53h with the fastening member 9.

  The extending portion 53 does not need to cover the entire surface of the outer core base portion 321 of the outer core piece 32m, and may have a size that can fix the combined body 10 to the case 4. By doing so, the material which comprises the interposed member 5 can be suppressed.

  In this example, the fixed portion 53f has a cantilever support structure in which one end side (the end surface interposed portion 52 side) is a support end and the other end side (the through hole 53h side at the tip) is a free end. (See FIG. 5). In the case of a cantilever support structure, if the fastening member 9 is passed through and tightened into the through hole 53h, the fixing portion 53f may become unstable. Therefore, as shown in FIG. 5, a reinforcing portion 54 that suppresses the swinging of the fixed portion 53f on the free end side is integrally formed on each of the split interposed members 5A and 5B. Here, the reinforcing portion 54 is formed in a triangular shape extending from the lower surface of the fixing portion 53f (the surface on the bottom plate portion 40 side of the case 4) toward the end surface interposed portion 52 and toward the pressing portion 51p. Has been. Since the pressing portion 51p is formed integrally with the end surface interposition portion 52, the reinforcing portion 54 is provided so that the pressing portion 51p causes the coil 2 to move the coil 2 to the bottom plate portion of the case 4 as the fixing portion 53f is fixed to the case 4. The action of pressing on the 40 side can be made to work reliably.

  In this example, the fixing portion 53f is formed so as to be positioned above the corner portion of the outer core base portion 321 of the outer core piece 32m, so that damage to the corner portion can also be suppressed.

  Examples of the constituent material of the interposition member 5 include polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), nylon 6 and nylon 66, polyamide (PA) resin, polybutylene terephthalate (PBT), and the like. ) Resin and thermoplastic resins such as acrylonitrile / butadiene / styrene (ABS) resin can be used. In addition, thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins can be used. The interposition member 5 can be easily manufactured by a known molding method such as injection molding of the above resin.

Case As shown in FIG. 3, the case 4 has a flat bottom plate portion 40 on which the combined body 10 is placed and a substantially rectangular frame shape standing from the bottom plate portion 40 so as to surround the periphery of the combined body 10. It is a bottomed container shape which has the side wall part 41 of this and opened on the opposite side (upper side) with the baseplate part 40. The reactor 1 can be protected from the external environment (dust, corrosion, etc.) and mechanical protection of the combination 10 by housing the combination 10 in the case 4. In this example, the bottom surface of the bottom plate portion 40 of the case 4 is fixed so as to contact the upper surface of an installation target (not shown) such as a cooling base, and the reactor 1 is installed on the installation target. Although FIG. 1 shows an installation state in which the bottom plate portion 40 is downward, there may be an installation state in which the bottom plate portion 40 is upward or sideward.

  At the four corners of the case 4, attachment portions 45 for attaching the combination 10 to the case 4 are provided. The mounting portion 45 is formed with a mounting hole 45h through which a fastening member 9 such as a bolt is inserted. The assembly 10 is fixed to the case 4 by aligning the mounting hole 45h and the through hole 53h of the fixing portion 53f, and by fastening the fastening member 9 through the mounting hole 45h and the through hole 53h.

  The case 4 shown in this example is a metal case in which the bottom plate portion 40 and the side wall portion 41 are integrally formed. In general, since metal has a relatively high thermal conductivity, if it is a metal case, the entire case can be used as a heat dissipation path, and heat generated in the assembly 10 can be efficiently applied to an external installation target (for example, a cooling base). Heat can be radiated well, and the heat dissipation of the reactor 1 can be improved. Examples of the constituent material of the case 4 include aluminum and its alloys, magnesium and its alloys, copper and its alloys, silver and its alloys, iron and austenitic stainless steel. When formed of aluminum, magnesium, or an alloy thereof, the case 4 can be lightened.

-Junction layer The reactor 1 shown in this example is provided with the joining layer 7 in the installation surface of the assembly 10, as shown to FIG. The bonding layer 7 is interposed between the lower surface of the coil 2 and the bottom plate portion 40 in the combined body 10. By providing the bonding layer 7, the combined body 10 can be firmly fixed to the bottom plate portion 40, and the movement of the coil 2 can be restricted, the heat dissipation can be improved, and the fixing to the installation target can be stabilized. The constituent material of the bonding layer 7 includes an insulating resin, particularly a ceramic filler, and has excellent heat dissipation (for example, a thermal conductivity of 0.1 W / m · K or more, more preferably 1 W / m · K or more, particularly 2 W / m · K or more) is preferable. Specific examples of the resin include thermosetting resins such as epoxy resin, silicone resin, and unsaturated polyester, and thermoplastic resins such as PPS resin and LCP. The bonding layer 7 may be formed by using, for example, a sheet-like material, coating, or spraying.

-Sealing resin part The sealing resin part 6 is a member which seals the assembly 10 with which the case 4 was filled and accommodated in the case 4, as shown in FIG. The sealing resin portion 6 is filled until the upper surface excluding both winding ends of the coil 2 in the combined body 10 is buried (see FIG. 2). The reactor 1 seals the combined body 10 with the sealing resin portion 6 to fix the combined body 10 to the case 4, and protects the combined body 10 from electrical and mechanical protection, protection from the external environment, and the coil 2. It is possible to reduce the vibration of the magnetic core 3 generated when energized and the noise caused by the vibration.

  In the present embodiment, since the combination 10 is fixed to the case 4 by the fixing portion 53f of the interposition member 5 that is a constituent member of the combination 10, even if the upper surface of the combination 10 is not covered with the sealing resin portion 6, The combined body 10 and the case 4 are firmly fixed. In this case, the constituent resin amount of the sealing resin portion 6 can be reduced.

  In this embodiment, since the coil 2 and the inner bottom surface 40m of the bottom plate portion 40 of the case 4 are firmly fixed in contact with each other, the lower surface of the outer core base 321 of the coil 2 and the outer core piece 32m and the case The constituent resin of the sealing resin part 6 is not interposed between the inner bottom face 40m of the bottom plate part 4 (see FIG. 2).

  For example, an epoxy resin, a urethane resin, a silicone resin, an unsaturated polyester resin, or a PPS resin can be used as a constituent material of the sealing resin portion 6. In particular, an epoxy resin and a urethane resin are preferable because they are soft and inexpensive. From the viewpoint of improving heat dissipation, the sealing resin portion 6 may be mixed with a ceramic filler having high thermal conductivity such as alumina or silica.

[Reactor manufacturing method]
The reactor 1 having the above-described configuration can be manufactured by, for example, a procedure of manufacturing the assembled body ⇒ housing and fixing the combined body 10 in the case 4 ⇒ filling and solidifying the unsolidified constituent resin of the sealing resin portion 6. it can.

-Production of an assembly First, the inner core piece 31m, ... and the gap material 31g, ..., and one outer core piece 32m are attached to one divided interposing member 5A. At this time, the pair of projecting portions 322 and 322 of one outer core piece 32m are inserted into the insertion holes 52h and 52h of the end face interposed portion 52 of the divided interposing member 5A, and the inner core piece is inserted into the inner interposed portion 51 of the divided interposing member 5A. A stack of 31 m,... And a gap material 31 g,. Then, one outer core piece 32m, the inner core piece 31m,... And the gap material 31g,. Next, the winding portions 2a and 2b are attached to the outer periphery of the inner interposed portion 51 of the divided interposed member 5A. Thereafter, the split interposition members 5A and 5B are engaged by the engaging portions 51e and 52e, and the pair of protrusions of the other outer core piece 32m are inserted into the insertion holes 52h and 52h of the end face interposition portion 52 of the other split interposition member 5B. 322 and 322 are inserted. The combined body 10 can be handled as an integral body in which the coil 2 and the magnetic core 3 (the inner core pieces 31m, ..., the gap members 31g, ... and the outer core pieces 32m, 32m) are positioned by the interposition member 5.

・ Storing and fixing the combined body in the case The combined body 10 is stored in the case 4 (see FIG. 3). Here, after the bonding layer 7 is disposed on the lower surface of the combined body 10, the combined body 10 is housed in the case 4. At this time, the fixing portion 53 f of the interposition member 5 of the assembly 10 is disposed on the attachment portion 45 of the case 4. The through hole 53f of the fixing portion 53f and the attachment hole 45h of the attachment portion 45 are aligned, and the fastening member 9 is passed through and fastened to the attachment hole 45h and the through hole 53h. The combination 10 is fixed to the case 4 by being fastened to the bottom plate 40 side.

  As the fixing portion 54 f is fixed to the case 4, the pressing portion 51 p presses the coil 2 against the inner bottom surface of the bottom plate portion 40 of the case 4. Since the fixing portion 54f and the pressing portion 51p are integrally formed, when the fixing portion 54f is tightened to the bottom plate portion 40 side of the case 4, the pressing portion 51p is interlocked with the fixing portion 54f and the bottom plate portion 40 of the case 4 is connected. Because it moves to the side. The pressing of the pressing portion 51p brings the coil 2 into contact with the inner bottom surface 40m of the bottom plate portion 40 of the case 4 (see FIG. 2).

  The case 4 in which the combined body 10 is stored is filled with an unsolidified constituent resin of the sealing resin portion 6. The unsolidified constituent resin filled in the case 4 covers the outer periphery of the coil 2 and the outer periphery of the magnetic core 3, and reaches the gap between the coil 2 and the magnetic core 3. Then, the constituent resin is solidified.

[Main effects]
In the reactor 1 described above, since the interposing member 5 includes the fixing portion 53f, the union body 10 can be fixed to the case 4 with the constituent members of the union body 10, and thus the union body 10 is disposed with respect to the case 4. It is easy to do and is excellent in the assembly workability of the reactor 1. Moreover, since the assembly 10 is fixed to the case 4 using the constituent members of the assembly 10, it is not necessary to prepare another member such as a conventional stay, and the number of parts can be reduced.

  Further, in the reactor 1, the interposed member 5 includes the pressing portion 51 p, so that the pressing portion 51 p presses the coil 2 against the inner bottom surface 40 m side of the bottom plate portion 40 of the case 4 as the fixing portion 53 f is fixed to the case 4. Since the action works, the coil 2 and the inner bottom surface 40m of the bottom plate portion 40 of the case 4 can be easily fixed in a contact state. The reactor 1 is excellent in heat dissipation because the coil 2 and the inner bottom surface 40m of the case 4 are in contact with each other.

  In the reactor 1, the example in which the fixing portion 53f of the interposition member 5 is arranged toward the corner portion of the case 4 has been described. For example, the fixing portion is in the thickness direction of the outer core base portion 321 of the outer core piece 32m. You may extend and arrange | position. In addition, the number of through holes formed in the fixed portion can be selected as appropriate.

  The reactor of the present invention includes various on-vehicle converters (typically DC-DC converters) mounted on vehicles such as hybrid vehicles, plug-in hybrid vehicles, electric vehicles, and fuel cell vehicles, and converters for air conditioners. It can utilize suitably for the component of a converter and a power converter device.

DESCRIPTION OF SYMBOLS 1 Reactor 10 Combination 2 Coil 2a, 2b Winding part 2r Connection part 2w Winding 3 Magnetic core 31m Inner core piece 31g Gap material 32m Outer core piece 321 Outer core base part 322 Protrusion part 4 Case 40 Bottom plate part 40m Inner bottom face 41 Side wall Part 45 attachment part 45h attachment hole 5 interposition member 5A, 5B split interposition member 51 inner interposition part 51f interposition piece 51p pressing part 51e engagement part 52 end face interposition part 52h insertion hole 52e engagement part 52d partition part 52s sensor holding part 53 extension Protruding part 53f Fixing part 53h Through hole 54 Reinforcing part 6 Sealing resin part 7 Joining layer 9 Fastening member (bolt)

Claims (3)

A coil having a winding part;
A magnetic core having an inner core piece entirely disposed in the winding portion and an outer core piece having a portion arranged outside the winding portion;
An interposition member having a portion interposed between the winding part and the magnetic core;
A bottomed square cylindrical case that houses a combination of the coil, the magnetic core, and the interposition member, and a reactor,
The interposition member is
An inner interposition part arranged in the winding part;
An end surface interposed portion interposed between the wound portion and the outer core piece;
An extending portion extending outward in the axial direction of the winding portion and disposed on the upper surface of the outer core piece,
The extension portion has a through hole of a fastening member, and is fastened to the inner bottom surface side of the case by the fastening member, and includes a fixing portion that fixes the combination to the case .
The inner interposed portion is a member that is formed integrally with the fixed portion, and is interposed between a region on the inner bottom surface side of the case on the inner peripheral surface of the winding portion and the magnetic core, and the fixed portion Along with fixing to the case, a pressing portion that presses the coil against the inner bottom surface of the case ,
The fixing portion is a plate-like piece of a cantilever support structure that extends toward each corner of the case, and has the through hole side as a free end and the opposite side as a connection end with the pressing portion side,
The intervening member connects a surface on the inner bottom surface side of the case in the fixed portion and a surface on the outer core piece side in the end surface intervening portion, and includes a reinforcing portion provided along a side surface of the outer core piece . The interposition member is configured by combining a pair of split interposition members that are divided in two in the axial direction of the winding portion,
One of the pair of split interposed member comprises said pressing portion, to claim 1, further comprising a tubular portion capable of housing all of the inner core pieces and the gap members disposed within the winding portion of the magnetic core The described reactor. The reactor according to claim 2 , wherein the pair of split interposition members include engaging portions that engage with each other.

Images