JP6557645B2 - Busbar joint structure and reactor - Google Patents

Description

  The present invention relates to a bus bar joint structure and a reactor for joining a bus bar to a coil of a reactor.

  In general, a large-capacity reactor is used for a drive system of a hybrid vehicle or an electric vehicle. These onboard reactors are configured by mounting a coil around the core. The core is entirely or partially embedded in the resin by molding for the purpose of insulation from the coil or the like, or is inserted into a cylindrical resin molded product.

  The reactor includes, as a main body and a reactor main body including the core and the coil as described above, and a member that houses the reactor main body and a cover that covers the case. Furthermore, a bus bar for connecting the end of the coil to an external device is also an essential member. The end of the coil is welded to the bus bar.

  Since the coil is covered with an insulating coating, the coating at the end of the coil is peeled off to provide a coating peeling portion, and the coating peeling portion and the bus bar are welded. As a conventional technique for welding two members, a technique is known in which two joining members are disposed at an incline and welding is performed in a state where the tip portions of the joining members are opposed to each other (for example, Patent Document 1). .

Japanese Patent No. 5842856

  When welding the end of the coil and the bus bar, there is not only the film peeling part but also the part where the film remains in the vicinity of the end of the coil. When the coil end and the bus bar are brought into contact with each other, the bus bar contacts the film. Touch. For this reason, the end of the coil and the bus bar are slightly separated. That is, in the preparation stage of the welding operation, the bus bar is lifted from the coating peeling portion by the thickness of the coil coating, and the adhesion between the welding surfaces of the two becomes low. As a result, the welding strength may be reduced.

  In addition, in order to bring the coil-side film peeling portion and the bus bar into close contact with each other, a clamping operation for tightening the end portion of the coil and the bus bar may be performed. In this case, if the tightening strength is strong, the welded portion and the coil coating are too close to each other, and the coil coating is strongly affected by the heat from the welding, and the coating may be deteriorated.

  The present invention has been proposed in order to solve the above-mentioned problems, and has a simple configuration in which an angle is formed at the base of the bus bar so that the bus bar is separated from the coil, and excellent adhesion regardless of the thickness of the coil coating. Provides a stable and reliable busbar joint structure and reactor that can prevent welding damage by suppressing the influence of heat during welding, ensuring high welding strength The purpose is to do.

In order to achieve the above object, the present invention is a bus bar joint structure for joining a bus bar to a coil of a reactor, and the bus bar includes the following components.
(1) a connecting portion for connecting an end portion of the coil;
(2) a root portion formed continuously with the connection portion.
(3) The root portion is provided with an angle with respect to the connection portion so as to be separated from the end portion of the coil.
(4) An insulating film is formed on the coil.
(5) The end of the coil is provided with a film peeling portion from which the film is peeled off.
(6) The root portion is provided with a bent portion that forms an angle with respect to the connection portion,
(7) The bent portion is disposed in the vicinity of the coating film peeling portion.
(8) The root portion is inclined so as to be separated from the connection portion side.
(9) The film peeling portion and the connection portion are arranged in parallel to each other,
(10) The coating film peeling portion and the bent portion are arranged to face each other.
(11) The inclined root portion is disposed at the boundary between the coating film peeling portion and the coating film.

Bus bus bar may be provided on the cover covering at least a portion of the reactor. Furthermore, instead of providing an angle at the base of the bus bar so that the bus bar side is away from the end of the coil, the end of the coil may be provided at an angle so that the end of the coil is away from the bus bar. The reactor provided with the said bus-bar is also 1 aspect of this invention.

  According to the present invention, the bus bar includes a root portion that is angled with respect to the connection portion so as to be away from the end portion of the coil, thereby ensuring excellent adhesion regardless of the thickness of the coil coating and welding strength. In addition, it is possible to improve the stability and reliability by suppressing the influence of heat during welding and avoiding damage caused by welding.

The perspective view of this embodiment. The principal part disassembled perspective view of this embodiment. The principal part expansion perspective view of this embodiment. The exploded perspective view of this embodiment. The perspective view of the annular core of this embodiment. The perspective view of the connection core of this embodiment. The disassembled perspective view of the U-shaped core of this embodiment and its resin molded product. The disassembled perspective view of the T-shaped core of this embodiment and its resin molded product. The principal part expansion perspective view of other this embodiment.

[1] Representative embodiment (configuration)
The configuration of a representative embodiment according to the present invention will be described below with reference to FIGS. The present embodiment is a reactor in which the bus bar joining structure according to the present invention is employed and the bus bar is joined to the coil.

  FIG. 1 is a perspective view of this embodiment. As shown in FIG. 1, the reactor 100 is provided with a case 2 and a cover 50 that covers the case 2 from above, and the reactor body 1 is housed inside the case 2 and the cover 50. The reactor body 1 is provided with connecting coils 6a and 6b covered with a resin film 19 (shown in FIGS. 2, 3 and 6). Coating stripping portions 11 and 12 from which the coating 19 is stripped are provided at the ends of the coupling coils 6a and 6b. As shown in FIGS. 1 to 4 and 6, reference numeral 11 denotes a coating peeling portion at the winding start end of the coupling coils 6 a and 6 b, and reference numeral 12 denotes a coating peeling portion at the winding end end of the connection coils 6 a and 6 b. It is.

  As shown in FIGS. 1 and 4, the reactor body 1 and the case 2 are fixed so that the relative positions of the reactor main body 1 and the case 2 are not changed by a support member 18 integrated with each resin molded product and a fixing member such as a bolt 23. Fixed in position. The cover 50 is a lid-like member that covers the opening of the case 2, and a side wall that contacts the side wall of the case 2 is provided around the cover 50.

[Bus bar]
As shown in FIGS. 1, 2, and 4, three bus bars 611 to 613 are embedded in the cover 50. The bus bars 611 to 613 are plate-like conductive members for connecting the coupling coils 6a and 6b to an external device (not shown) such as an external power source, and are made of, for example, copper or aluminum. The bus bars 611 to 613 are welded to the film peeling portions 11 and 12 formed at the ends of the coupling coils 6a and 6b, so that both are electrically connected.

  The arrangement configuration of the bus bars 611 to 613 will be described with reference to FIGS. 1 and 2. FIG. 2 is an exploded perspective view of the cover 50, the coupling coils 6a and 6b, and the bus bars 611 to 613. As shown in FIG. 2, the bus bar 611 has a terminal strip 641 formed on the cover peeling portion 11 and the cover 50 at the beginning of the connection coil 6b (in FIG. 1, the upper left side of the cover 50, and the right side of the cover 50 in FIG. 2). And is embedded in parallel to the long side of the reactor body 1.

  The bus bar 612 has a crank shape that connects the coating stripping portion 12 at the end of winding of the connecting coil 6a and the terminal block 642 formed on the cover 50 (on the right side of the cover 50 in FIG. 1 and on the left side of the terminal block 641 in FIG. 2). And is embedded along the bus bar 611 in parallel with the long side of the reactor body 1. Therefore, in the surface portion of the cover 50, the embedded portions of the bus bar 611 and the bus bar 612 are raised.

  The bus bar 613 includes a terminal strip 643 (the lower left of the terminal block 642 in FIG. 1, FIG. 2). Is a member that connects the terminal block 642 and the terminal block 644 (in FIG. 1 to the lower right side of the cover 50 and in FIG. 2 the left side of the cover 50). Since the base 644 is close, it is a member having a substantially T-shape as a whole. Therefore, the surface of the cover 50 is raised in a T shape in accordance with the shape of the bus bar 613.

  In the bus bars 611, 612, one end of the portion extending in the longitudinal direction is provided with a connecting portion 71 with the coating stripping portions 11, 12 of the coupling coils 6a, 6b, and the other end of the portion extending in the longitudinal direction. Is provided with a connection portion 61b for connection to an external wiring. In the T-shaped bus bar 613, the end portions of the side portions bent at right angles from one end portion of the T-shaped horizontal bar portion and the end portions of the T-shaped vertical bar portion are coated stripped portions of the connecting coils 6a and 6b. The connection part 71 with 11 and 12 is provided. Further, in the T-shaped bus bar 613, a connecting portion 61b for connecting to an external wiring is provided at one end of the T-shaped horizontal bar portion and the end of the T-shaped vertical bar portion. That is, the bus bar 613 is provided with two connection portions 61b, and when combined with the connection portions 61b of the bus bars 611 and 612, four connection portions 61b are provided. Each of these four connection portions 61b is provided with a through hole 61c for screwing the bus bars 611 to 613 and the external wiring. The through holes 61c of the bus bars 611 to 613 are installed in the terminal blocks 641 to 644 on the cover 50 side.

  The connection part 71 and the connection part 61b in each bus bar 611-613 are exposed to the surface of the cover 50, and the circuit pattern formed by the conductor part between the connection part 71 and the connection part 61b in the bus bar 611-613 is the cover 50. Buried inside. In this manner, the three bus bars 611 to 613 are installed integrally with the cover 50.

[Bus bar joint structure]
FIG. 3 is an enlarged perspective view of a main part of the present embodiment. As described above with reference to FIG. 2, the connection portions 71 connected to the film peeling portions 11 and 12 of the coupling coils 6 a and 6 b are provided at the ends of the bus bars 611 to 613. As shown in FIG. 3, the connecting portion 71 faces the coating peeling portions 11 and 12 of the coupling coils 6a and 6b, and the peripheral portion including the upper edge portion is welded. The code | symbol 73 shown in FIG. 3 has shown the welding part. The connecting portion 71 is disposed so as to face each other with the same width as the coating stripping portions 11 and 12 of the coupling coils 6a and 6b.

  Each of the bus bars 611 to 613 is provided with a root portion 72 that is formed continuously from the connection portion 71 and extends downward integrally from the connection portion 71. That is, the root portion 72 is configured to hold the connection portion 71 on the front end side of the bus bars 611 to 613. The root portion 72 is provided with a bent portion 72a at a portion in contact with the connecting portion 71. By the presence of the bent portion 72a, the root portion 72 is provided at an acute angle with respect to the connecting portion 71. ing. The bent portion 72a is disposed in the vicinity of the film peeling portions 11 and 12.

  That is, the base portion 72 has the end portion on the connection portion 71 side as the tip end portion of the root portion 72 and the end portion on the opposite side to the tip portion in the longitudinal direction of the root portion 72 as the base end portion of the root portion 72. The end portions are arranged in the thickness direction of the end portions of the connecting coils 6a and 6b and away from the end portions of the connecting coils 6a and 6b. Accordingly, the root portion 72 is configured to incline away from the coating stripping portions 11 and 12 from the connection portion 71 side toward the base end portion direction of the root portion 72.

  At this time, the inclined portion of the root portion 72 starts from the film peeling portions 11 and 12 of the coupling coils 6a and 6b. That is, the bent portion 72 a of the root portion 72 is disposed in the vicinity of the coating film peeling portions 11 and 12, so that the inclined portion of the root portion 72 is disposed at the boundary between the coating film peeling portions 11 and 12 and the coating film 19. Such a connection part 71 and the root part 72 are comprised from the plate-shaped member formed integrally.

[Overall structure of the reactor]
The overall configuration of the reactor 100 will be described. FIG. 4 is an exploded perspective view of the reactor 100. FIG. 4 shows a state in which the reactor 100 is divided into four parts, that is, the reactor main body 1, the case 2, the filler 3, and the cover 50. The bus bars 611 to 613 are originally members embedded on the cover 50 side, but here are arranged on the reactor main body 1 side in order to show the joining state of the connecting coils 6a and 6b with the film peeling portions 11 and 12. doing.

[Reactor body]
The reactor body 1 has a rounded rectangular shape with two long sides and two short sides (a rectangular shape with rounded corners), and the case 2 has a rectangular parallelepiped shape with an open top surface corresponding to the reactor body 1. ing. As shown in FIG. 4, the reactor body 1 includes a θ-shaped annular core 9 and two connecting coils 6 a and 6 b wound around the legs of the annular core 9.

[Annular core]
The annular core 9 constituting the reactor body 1 will be described with reference to FIG. As shown in FIG. 5, the annular core 9 is formed by combining two U-shaped cores 4a and 4b and two T-shaped cores 5a and 5b. That is, the annular core 9 abuts both ends of the U-shaped cores 4a and 4b and the left and right ends of the T-shaped cores 5a and 5b, and applies and bonds the adhesive 8 between them. , 5b are combined so that a predetermined gap 10 is formed between the central projections 7a, 7b.

  Accordingly, the annular core 9 has a pair of opposing yoke portions, a central middle leg provided in parallel with the yoke part, and a pair of coils 6a and 6b provided on both sides of the middle leg, respectively. A portion (hereinafter referred to as an outer leg) is formed. Dust cores may be used as the U-shaped cores 4a and 4b and the T-shaped cores 5a and 5b.

  Further, as the U-shaped cores 4a and 4b and the T-shaped cores 5a and 5b, other laminated cores in which a ferrite core or silicon steel is laminated may be used alone or in combination. Furthermore, a spacer may be provided in a portion where the adhesive 8 is applied. The gap 10 may be an air gap or a gap provided with a spacer.

[Connection coil]
The connection coils 6a and 6b constituting the reactor body 1 will be described with reference to FIG. As shown in FIG. 6, each connection coil 6a, 6b forms two coils 6a-1, 6a-2 or 6b-1, 6b-2 using one conductor. In the connecting portion 63 of the coils 6a-1, 6a-2 or 6b-1, 6b-2, the flat wires are connected on the same plane in a plane perpendicular to the winding axis direction of the coil. Such connecting coils 6a and 6b are attached to the parts constituting the outer legs of the U-shaped cores 4a and 4b on both sides of the middle leg (see FIG. 4).

  When the connecting coils 6a and 6b are mounted on the annular core 9, one conductor is wound around the outer periphery of one outer leg to form the first coils 6a-1 and 6b-1, and the same conductor is The second coil 6a-2, 6b-2 is formed by being wound around the outer leg on the opposite side. Therefore, as shown in FIG. 4, one film 6a, 6b is provided with a coating peeling portion 11 at the beginning of winding and a coating peeling portion 12 at the end of winding, one on each side of the middle leg.

  As the connection coils 6a and 6b, one in which various conductors are wound can be used. In the present embodiment, an edgewise coil obtained by edgewise winding a rectangular conductor is used. The film peeling portions 11 and 12 at the beginning and end of winding of each of the connecting coils 6a and 6b may be provided on the middle leg side like the coil 6a, or may be provided on the yoke side side like the coil 6b. In this case, both the two coils 6a and 6b may be provided on either the middle leg side or the yoke part side.

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

  The connecting coils 6a and 6b are wound in such a direction that the DC magnetic fluxes generated from the connecting coils 6a and 6b cancel each other. Further, the connecting coils 6 a and 6 b are provided on the annular core 9 so that the magnetic flux density on the outer periphery of the reactor body 1 is low in the two spaces located between the reactor body 1 in the long side direction of the reactor body 1. It is installed. That is, since the middle leg is formed on the annular core 9, when the reactor 100 is energized, the magnetic flux density is low around the yoke portion that is the short side of the annular core 9.

[Resin molding]
In the annular core 9, the U-shaped cores 4 a and 4 b and the T-shaped cores 5 a and 5 b are respectively embedded in dedicated resin molded products. These cores 4a, 4b, 5a, 5b are formed integrally with the resin molded product by injecting and solidifying the resin into the mold in a state of being set in the mold of each resin molded product. Yes.

  The resin molded product is a member that insulates each of the cores 4a, 4b, 5a, and 5b and the coupling coils 6a and 6b, and also a member that fixes a support member for fixing the reactor body 1 to the case 2. As the main material of the resin molded product, for example, unsaturated polyester resin, urethane resin, epoxy resin, BMC (bulk molding compound), PPS (polyphenylene sulfide), PBT (polybutylene terephthalate) and the like can be used.

  The resin molded product 13 for the U-shaped core that covers the U-shaped cores 4a and 4b will be described with reference to FIG. The resin molded product 13 for the U-shaped core 4a shown in FIG. 7 includes a coil mounting portion 15 that covers the left and right leg portions of the U-shaped core 4a, and a yoke covering portion 16 that covers the yoke portion of the U-shaped core 4a. An opening that exposes the end face of the U-shaped core 4a is provided in a portion corresponding to the joint surface between the U-shaped core 4a and the T-shaped core 5a in the coil mounting portion 15, and a T-shaped core is provided around the opening. A rib 17 is provided for inserting the end of the resin molded product 14a for use.

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

  The resin molded product 14 for the T-shaped core that covers the T-shaped cores 5a and 5b will be described with reference to FIG. As shown in FIG. 8, the resin molded product 14 for the T-shaped core 5b includes a coil mounting portion 19 that covers the leg portion of the T-shaped core 5b, and a middle leg covering portion 20 that covers the central protrusion 7b of the T-shaped core 5b. With. The end face on the U-shaped core 4b side of the coil mounting portion 19 is an opening through which the end face of the internal T-shaped core 5b is exposed. Around this opening is formed a recess 21 into which a rib 17 provided on the resin molded product 13 for the U-shaped core 4b is fitted.

  Since the end surface of the central protrusion 7b of the T-shaped core 5b faces the end surface of the central protrusion 7a of the T-shaped core 5a via the gap 10, this portion of the middle leg covering portion 20 is the entire end surface of the T-shaped core 5b. Is covered. When a gap is formed using a spacer instead of the gap 10 or no gap is formed at all, an opening may be provided in the middle leg covering portion 20 to expose the end face of the central projection 7b.

  A cylinder into which a bolt 23 (shown in FIG. 1) as a fixing member is inserted when the reactor body 1 is fixed to the case 2 on the opposite side of the middle leg covering portion 20 of the resin molded product 14 for the T-shaped core 5b. A shaped collar 22 is embedded. The cylindrical collar 22 is set in the mold together with the U-shaped cores 4a and 4b and molded at the time of molding the resin molded product 13 for the U-shaped core. The resin molded product 14 for the T-shaped core 5a has the same configuration as the resin molded product 14 described above.

  The resin molded product 13 for the U-shaped core and the resin molded product 14 for the T-shaped core cover the periphery of each core except for the butted portion of each core. However, it is necessary to use a jig for positioning each core and support metal fitting in the mold. Therefore, an opening where no resin is present is formed in a portion corresponding to the jig, and the surface of each core is exposed in that portion.

[Case]
The case 2 is formed of a metal having high thermal conductivity, and has a function as a heat dissipation member for heat generated from the reactor body 1 while accommodating the reactor body 1. Aluminum or magnesium can be used as the metal with high thermal conductivity forming the case 2. Moreover, the case 2 does not necessarily need to be a metal, and it is also possible to use a resin excellent in thermal conductivity or a resin in which a metal heat sink is embedded in a part of the resin.

[Filler]
A gap having a predetermined size is provided between the case 2 and the reactor body 1, and the filler 3 shown in FIG. 4 is filled and solidified in the gap. As the filler 3, it is desirable to use a resin having some elasticity even when solidified. For example, an epoxy-based, polyacrylate-based, or silicone-based resin potting agent mixed with a heat dissipation material such as aluminum oxide or aluminum nitride can be used by adjusting the degree of curing.

(Action and effect)
In the present embodiment as described above, the bus bars 611 to 613 hold the connection portion 71 that connects the coating stripping portions 11 and 12 of the coupling coils 6a and 6b, and also from the coupling coils 6a and 6b. By including the root portion 72 having the bent portion 72a that is angled so that the bus bars 611 to 613 are separated from each other, the following operations and effects are obtained.

[Improvement of welding strength]
The base portion 72 of the bus bars 611 to 613 is inclined at an angle so that the bus bars 611 to 613 are separated from the coupling coils 6a and 6b by providing a bent portion 72a. Therefore, even when the coating strips 11 and 12 of the coupling coils 6a and 6b are brought into contact with the connection portions 71 of the bus bars 611 to 613, even if the coating 19 of the coupling coils 6a and 6b has a thickness, the thickness of the coating 19 is increased. Regardless, the coating stripping portions 11 and 12 of the coupling coils 6a and 6b and the connection portions 71 of the bus bars 611 to 613 can be strongly adhered.

  In addition, in the present embodiment, since the film peeling portions 11 and 12 of the coupling coils 6a and 6b and the connection portions 71 of the bus bars 611 to 613 are not inclined with respect to each other, a large contact area between them can be taken and welding is performed. The range never becomes a “point”. According to such this embodiment, the welding part 73 can ensure strong welding strength, and the performance as the reactor 100 is stabilized.

[Improving welding efficiency]
Moreover, the connection part 71 and the root part 72 consist of a plate-shaped member formed integrally, and are arrange | positioned in parallel with the film peeling parts 11 and 12 of the connection coils 6a and 6b. Further, in the bus bars 611 to 613, the bent portion 72a of the base portion 72 faces the coating peeling portions 11 and 12 of the coupling coils 6a and 6b. In such an arrangement, the inclination starts from the bent portion 72a of the root portion 72 (see FIG. 3).

  Therefore, the root portion 72 works to press the connecting portion 71 against the coating stripping portions 11 and 12 of the coupling coils 6a and 6b, and the adhesion between them is increased. As a result, it is possible to omit a clamping operation for strongly fastening the coating film peeling portions 11 and 12 and the connection portion 71 of the coupling coils 6a and 6b, and the efficiency of the welding operation is improved.

[Avoidance of damage caused by welding heat]
In the present embodiment, since the bent portion 72a of the root portion 72 starts from the film peeling portions 11 and 12 of the coupling coils 6a and 6b (see FIG. 3), the bent portion 72a of the root portion 72 becomes the film peeling portions 11 and 12. It arrange | positions adjacently and the inclined part of the root part 72 is arrange | positioned in the boundary of the film peeling parts 11 and 12 and the film 19. FIG. Due to the presence of such an inclined portion of the root portion 72, the coating peeling portions 11 and 12 of the coupling coils 6a and 6b can be sufficiently separated from the root portion 72 of the bus bars 611 to 613.

  Therefore, it is possible to reliably prevent the adhesion between the coating stripping portions 11 and 12 and the bus bars 611 to 613 from being inhibited by the thickness of the coating 19 generated at the boundary between the coating stripping portions 11 and 12 and the coating 19. As a result, the coating film 19 of the coupling coils 6a and 6b is not easily affected by heat due to welding, and there is no fear that the coating film 19 deteriorates. Thereby, the bus bars 611 to 613 can avoid damage due to welding heat, and the reliability is improved.

[Prevents damage to the coating coil]
Since the connection part 71 which is an end part of the bus bars 611 to 613 is vertically raised, when the cover 50 is to be put on the case 2 from above, the connection part 71 of the bus bars 611 to 613 is connected to the coupling coil 6a, There is a risk of hitting the coating stripping portions 11 and 12 of 6b, such as scraping the coating 19 of the coupling coils 6a and 6b.

  However, in the present embodiment, since the base portion 72 of the bus bars 611 to 613 is angled, the cover 50 can be covered with the case 2 while sliding in the horizontal direction obliquely from above. For this reason, the connection part 71 of the bus bars 611 to 613 does not hit the coating film peeling parts 11 and 12 of the coupling coils 6a and 6b. Therefore, damage to the connecting coils 6a and 6b can be prevented, and the working efficiency is improved.

[2] Other Embodiments The present invention is not limited to the above-described embodiment, and can be embodied by modifying the constituent elements without departing from the scope of the invention in the implementation stage. For example, various embodiments can be configured by appropriately combining a plurality of constituent elements disclosed in the above embodiments. Moreover, you may delete some components from all the components shown by embodiment.

  For example, the base 72 of the bus bars 611 to 613 may be angled so that the bus bars 611 to 613 are separated from the coil, and the angle can be changed as appropriate. Specifically, as shown in FIG. 9, it may be L-shaped. Even in such an embodiment, the same effects as in the above embodiment can be obtained.

  The bus bar of the present invention is not limited to the one for a large current, and includes a flexible conductor for a small current, a thin single wire, and a stranded wire. Further, not the end of the bus bar but the end of the coil may be arranged at an angle so as to be away from the bus bar.

  The number and shape of the bus bars installed on the cover 50 are not limited to those illustrated. The number of bus bars can be appropriately changed depending on the number of coils. In particular, in this embodiment, as the coils to be attached to the annular core, the connected coils 6a and 6b, in which two coils are produced by one conductor, are used, so the number of ends is small compared to the number of coils. When the connecting coil is not used, there are more coil ends. Therefore, it is necessary to connect the coil ends, and the number and shape of the bus bars can be changed as appropriate. Although it is preferable to embed all the conductor portions of the bus bar in the resin molded product, only a part may be embedded. Further, a groove may be formed in a resin molded product constituting the cover, and a bus bar may be fitted therein so that the cover 50 holds the groove.

  The shape of the coils 6a and 6b wound around the core can also be changed as appropriate. The coils 6a and 6b are wound around the left and right legs of the θ-shaped core, and the coil 6a is wound around the yoke portion of the θ-shaped core. , 6b may be wound. When a circular or square loop core is used, the coils 6a and 6b may be wound around the left and right legs, or the coils 6a and 6b are wound around only one of the two legs. Also good.

  As resin moldings, in addition to insert molding of the core inside, only hollow cylindrical or box-shaped resin moldings are produced in advance, and the core is fitted inside and fixed with adhesive You may also use. Further, after joining the split cores, the annular core can be insert-molded or incorporated into the resin molded product.

  The member for fixing the case 2 and the cover 50 is not limited to screwing such as bolts, but various types such as press-fitting of rivets and pins, press-fitting protrusions provided on the cover 50 or the case 2 into holes and recesses of the other party, etc. The configuration may be adopted. The connection between the coil coating peeling portions 11 and 12 and the bus bar is not limited to welding, and a connector may be used, or screws such as bolts and nuts may be used. The connection between the bus bar and external wiring is not limited to bolts and nuts. It may be by connector or welding.

  In the illustrated embodiment, the cover 50 is fixed to the case 2 and the filler is injected after welding the coil end and the bus bar. However, the filler is injected and solidified in a state where the reactor body 1 is accommodated in the case 2. Therefore, the cover 50 can be fixed and the bus bar and the coil end can be welded.

  The material of the cover 50 may be the same as the resin molded product that covers the annular core, such as PPS (polyphenylene sulfide), and other materials may be used as long as the material is not damaged by the bus bar or the ambient temperature. You may do it. When the cover 50 is made of a transparent resin, there is an advantage that a circuit pattern constituted by an internal bus bar and a state inside the reactor can be confirmed.

  In the illustrated embodiment, the case 2 is used as a housing member for the reactor body 1, but is not necessarily limited to the case where the reactor body is fixed to the case. The entire reactor may be covered with a cover, and an installation surface may be provided and fixed together with the cover. Further, the reactor main body may be fixed to a plate-like or block-like member, and the whole may be covered with a cover. In that case, you may provide the circuit pattern comprised by the bus bar provided in a cover not on the upper surface of a reactor but on the side surface.

DESCRIPTION OF SYMBOLS 1 ... Reactor main body 2 ... Case 3 ... Filler 4a, 4b ... U-shaped core 5a, 5b ... T-shaped core 6a, 6b ... Coil 7a, 7b ... Center protrusion 8 ... Adhesive 9 ... Ring core 10 ... Gap 11, DESCRIPTION OF SYMBOLS 12 ... Film peeling part 13,14 ... Resin molded product 18 ... Support metal fitting 19 ... Film 50 ... Cover 611-613 ... Bus bar 71 ... Connection part 72 ... Base part 72a ... Bending part 73 ... Welding part 100 ... Reactor

Claims (4)

A bus bar joint structure for joining a bus bar to a coil of a reactor,
The bus bar
A connecting portion for connecting an end of the coil;
A root portion formed continuously in the connection portion,
The root portion is provided at an angle with respect to the connection portion so as to be separated from an end portion of the coil,
An insulating film is formed on the coil,
The end of the coil is provided with a film peeling portion from which the film is peeled,
The root portion is provided with a bent portion that forms an angle with respect to the connection portion,
The bent portion is disposed in proximity to the film peeling portion,
The root portion is inclined away from the connecting portion side,
The film peeling part and the connection part are arranged in parallel to each other,
The film peeling part and the bent part are arranged facing each other ,
The inclined base portion is arranged at the boundary between the coating film peeling portion and the coating film .   The bus bar joining structure according to claim 1, wherein the bus bar is installed on a cover that covers at least a part of the reactor. End, the bus bar joint structure according to claim 1 or 2, characterized in that arranged at an angle away from the bus bar of the coil. Reactor characterized by comprising the bus bar according to any one of claims 1-3.

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