JP7530044B2 - Boost Reactor Device - Google Patents

Description

The present invention relates to a boost reactor device that is mounted, for example, on electric vehicles and hybrid vehicles, and more specifically, to a boost reactor device in which a coil portion made of rectangular wire is wound around a part of a core that forms a closed magnetic circuit.

For example, a known boost reactor device for HEVs has a reactor body housed in an aluminum case filled with thermally conductive resin in order to improve the heat dissipation effect. A known configuration of the reactor body of such a conventional boost reactor device is one in which a pair of U-shaped cores are formed into an annular core portion by butting the tips of both legs of the cores against each other, and two coil portions are arranged by winding a coil made of rectangular wire around each of the butted legs of the U-shaped cores (see Patent Document 1).
On the other hand, HEVs and the like are required to have as compact a mounting space for electronic components as possible, and in boost reactor devices for HEVs, a major priority is to make the device as low-profile as possible. Therefore, in the case of a boost reactor device configured as described above, the input/output terminal portions of the flat wire coil are pulled out horizontally without being lifted upward from the top surface of the wound coil.
Furthermore, since insulation is required between the flat wire coil and the aluminum case, the height of the aluminum case is arranged to be lower than the pull-out position of the input/output terminal portion of the flat wire.

Because the height of the aluminum case is lower than the position where the rectangular wire is pulled out, the upper part of the wound coil is exposed from the thermally conductive resin filled in the aluminum case. For this reason, the maximum heat generating part of the boost reactor device is generally biased toward the upper part of the wound coil, and since the rated temperature of the device is based on the maximum temperature, the output of the boost reactor device must be reduced to match the temperature of the upper part of the wound coil.
Therefore, there has been a demand for a configuration in which the reactor body can be immersed in the thermally conductive resin up to as high an extent as possible while reducing the height of the device.
Specific examples of conventional boost reactor main bodies constructed in response to such demands include those roughly shown in FIGS. 9A, 9B and 9C.

Patent Publication 2010-166013

However, the conventional boost reactor device for HEVs having the configuration shown in Figs. 9A, 9B and 9C has the following problems.
That is, as shown in FIG. 9A(b), when terminal portions 303B, 304B of each coil portion 303A, 304A are bent edgewise while keeping the lengths of each coil portion 303A, 304A equal and pulled out to the same side of the reactor, in order to prevent the terminal portions of each coil portion 303A, 304A from crossing each other, terminal portion 303B of coil portion 303A farther from this side must be pulled out at a position at least the coil width higher than terminal portion 304B of coil portion 304A closer to the side, which increases the height of the entire device and makes it impossible to meet the demand for a low profile.
On the other hand, as shown in Figure 9A (a), if the terminal portions 303B, 304B of each coil portion 303A, 304A are bent edgewise and each coil portion 303A, 304A is pulled out to the nearby side, the demand for a low height can be met. However, since terminal blocks and insulating resin parts corresponding to the terminal portions 303B, 304B of the coil portions 303A, 304A are required for each coil portion 303A, 304A, this is difficult to adopt from a cost standpoint.

Also, as shown in Figures 9B(a) and (b), in order to increase the core volume of the base core parts 410A and B where the coil parts 403A and 404A are not arranged, the height of this part is made higher than that shown in Figures 9A(a) and (b), and a shape has been devised to be equal to the height of the upper surface position of the coil parts 403A and 404A. However, even with such a shape, the same problems as those in Figures 9A(a) and (b) above occur.

9A(a), (b) and 9B(a), (b), a method has been devised in which the wiring is pulled out in a direction perpendicular to the direction in which terminal portions 303B, 304B, 403B, 404B of coil portions 303A, 304A, 403A, 404A are pulled out. When a welding method is used to join the wide surfaces of terminal portions 303B, 304B, 403B, 404B of each coil portion 303A, 304A, 403A, 404A to the wide surface of a bus bar such as a terminal block, it is necessary to set the wide surface of the rectangular wire to be parallel to the bus bar of the terminal block, etc., but if left in this state, the wide surface of the rectangular wire will be set to be perpendicular to the wide surface of the bus bar. 9C(a), terminal portions 503B, 504B of coil portions 503A, 504A are bent flatwise, and then twisted 90° to the desired state. However, if terminal portions 503B, 504B are twisted 90°, a welding method for joining the wide surfaces of terminal portions 503B, 504B to the wide surfaces of bus bars such as terminal blocks is possible, but twisting the rectangular wire requires extra space above base core portions 510A, B where coil portions 503A, 504A are not disposed, which goes against the demand for compactness and low height.
Furthermore, as shown in Figure 9C(b), in the same manner as in Figures 9B(a) and (b), in the case where the height of the base core portions 510A, B in which the coil portions 503A, 504A are not arranged is increased to be equal to the height of the upper surfaces of the coil portions 503A, 504A, the positions of the terminal portions 503B, 504B are even higher than in Figure 9C(a), which goes against the demand for compactness and low height.

In this way, in any of the boost reactor devices of the configurations of Figures 9A, B, and C using a U-core, the process of pulling out the terminal portions 303B, 304B, 403B, 404B, 503B, and 504B of the two coil sections 303A, 304A, 403A, 404A, 503A, and 504A provided to achieve magnetic balance prevents the device from being made more compact and low-profile.
Furthermore, in any of the boost reactor devices having the configurations shown in Figures 9A, 9B, and 9C described above, it is difficult to immerse the entire reactor body in the above-mentioned thermally conductive resin, making it impossible to improve the heat reduction effect in the upper part of the reactor body, and the output of the boost reactor device must be reduced.

The present invention has been made to solve the problems described above, and aims to provide a boost reactor device that can drastically improve the problem of making the entire device compact and low-profile while allowing the entire reactor body, including the coil section, located inside the case, to be immersed in thermally conductive resin for cooling.

In order to solve the above problems, the boost reactor device according to the present invention comprises:
a pair of E-shaped cores each having corresponding end faces butted together to form a closed magnetic circuit;
In a state where the pair of E-shaped cores are butted against each other to form a closed magnetic circuit, a coil portion made of a rectangular wire is attached in a wound state to a center leg portion of the pair of E-shaped cores;
a metal case comprising: a metal case body having a height capable of housing the entire assembly in which the pair of E-shaped cores and the coil section are combined with each other, and having a notch portion on a side wall portion on the side through which the input end and output end of the coil section pass, the notch portion having a depth to allow the input end and output end to pass through; and a bracket that engages with the notch portion, is supported by the metal case body while closing the notch portion, and has a pair of through holes through which the input end and the output end are inserted while being in close contact with each other;
a cooling filler filled in the metal case until the entire assembly is immersed therein ;
The height of the outer leg portion of the E-shaped core is made lower than the height of the center leg portion .

It is also preferable that the material forming the metal case body is made of aluminum, and the material forming the bracket is made of insulating resin.
It is also preferable that a groove-shaped guide portion be formed at the engaging portion of the bracket with the metal case body, the guide portion fitting with an edge portion of the notch of the metal case body.

The cooling filler is preferably made of a resin having fluidity.
It is also preferable that each of the pair of through holes provided in the bracket is elongated in the height direction of the metal case body so that the rectangular wire can be inserted therethrough in an upright state .

As described above, the boost reactor device of the present invention is premised on a configuration in which a pair of E-shaped cores and one coil made of rectangular wire are combined.
Conventionally, as explained using Figures 9A, 9B, and 9C, it was common knowledge among those skilled in the art to combine two coil sections made of a pair of U-shaped cores and rectangular wire. However, in this invention, the inventors of the present invention came to the conclusion that the object of the present invention could be achieved by adopting a configuration in which a pair of E-shaped cores and one coil section made of rectangular wire are combined in the boost reactor device. This was due to a change in thinking on the part of the inventors, and the following historical background was a major factor in this conclusion.

In other words, in the past, it would have been thought that there would have been no room for the idea of combining a pair of E-shaped cores and a single coil made of rectangular wire to create a boost reactor device that could achieve the objectives of this invention. However, by focusing on technological advances such as the evolution of core materials and changes in operating frequencies, the inventors of this application were able to change their thinking and arrive at the present invention.

First, the evolution of core materials means that the flexibility of core shapes has improved significantly. Conventional cores have been "cut cores" made from processed silicon steel sheets, and are generally made by stacking several dozen sheets of sheet material, bending them into an O-shape to form a closed magnetic circuit, and then cutting them in the middle to produce a pair of U-shaped cores.
For this reason, it has been difficult to use a different core shape (closed magnetic circuit configuration shape) for the boost reactor device. Also, the coil portion that can be combined with such a U-shaped core is usually wound around each leg, so that it is configured as a pair.
However, as times have changed, dust cores, which are made by powdering similar materials and kneading them together, have become known. Dust cores are made by molding magnetic materials in a mold, and since it has become possible to mold cores of various shapes, people have begun to search for core shapes that can achieve the desired characteristics.

On the other hand, the above-mentioned change in operating frequency is as follows.
It has been known that the inductance required of a reactor is smaller when the operating frequency is high than when the operating frequency is low.
On the other hand, when the frequency of elements that switch large amounts of power on and off increases, power loss increases and heat generation becomes excessive, causing major obstacles in system configuration.
As times change, improvements have been made to components, making it possible to reduce power loss and systems that switch at high frequencies gradually becoming available, making it possible to use compact reactors with reduced inductance.

Taking note of these technological advances, the inventors of the present application have come up with the invention of a boost reactor device with a basic structure that combines a single rectangular wire coil with the center leg of a coil structure in which a pair of E-shaped cores are butted together, which provides a large inductance per coil turn.

Even when adopting a configuration in which a pair of E-shaped cores and one flat wire coil section made of flat wire are combined in this way, it is necessary to take out both ends of the coil wound around the middle leg of the E-shaped core as the input end and output end. However, in the boost coil of the present invention, a notch is provided in the case body, a bracket made of insulating resin is engaged with the notch, and the input end and output end of the coil section are drawn out through a through hole drilled in the bracket, and these input end and output end are connected to external terminals. This allows the input end and output end to be drawn out of the case from the upper position of the coil winding section without lifting them in the height direction.

Furthermore, by dividing the case into a metal case body and an insulating resin bracket in this manner, insulation between the case body and the coil terminal portions (input end and output end) can be ensured.
Furthermore, the entire reactor body can be housed within the case and filled with thermally conductive resin so that the entire reactor body is immersed. By achieving uniform heat distribution overall, the temperature of the maximum heat-generating part can be reduced, making it possible to reduce the height of the device while suppressing a decrease in the rated temperature of the device.

1 is a perspective view showing an entire boost reactor device according to an embodiment of the present invention; 1B is a perspective view showing the boost reactor device shown in FIG. 1A in a state before a filler is filled therein; FIG. FIG. 1B is a cross-sectional perspective view of the boost reactor device shown in FIG. 1A. FIG. FIG. 1A shows a reactor body in this embodiment, where (a) is a perspective view of the coil portion, (b) is a perspective view of the E-shaped core, and (c) is a perspective view of the coil portion and the core combined (the core is shown sealed in a bobbin (a resin molded body)). As a comparison with this embodiment, the temperature distribution under continuous load in a configuration in which the upper surface of the coil is exposed from the filler is shown by changes in concentration ((a) is a cross-sectional front view, (b) is a cross-sectional plan view, and (c) is a cross-sectional side view). As a comparison with this embodiment, in a configuration in which the upper surface of the coil is exposed from the filler, the temperature distribution when a large load is applied for a short period of time after a continuous load is applied is shown by the change in concentration ((a) is a cross-sectional front view, (b) is a cross-sectional plan view, and (c) is a cross-sectional side view). In this embodiment, the temperature distribution under continuous load is shown by the change in concentration in a non-exposed form in which the upper surface of the coil is covered with a filler ((a) is a cross-sectional front view, (b) is a cross-sectional plan view, and (c) is a cross-sectional side view). In this embodiment, in a non-exposed configuration in which the upper surface of the coil is covered with a filler, the temperature distribution when a large load is applied for a short period of time after a continuous load is applied is shown by the change in concentration ((a) is a cross-sectional front view, (b) is a cross-sectional plan view, and (c) is a cross-sectional side view). 4A, 4B, and 4C are perspective views showing specific aspects of an E-shaped core in a reactor assembly according to an embodiment of the present invention. The figures show a configuration in which a U-shaped core is used as a conventional technology, and the core height is all made the same by using coil wiring that is bent edgewise ((a) is a perspective view of one example, and (b) is a perspective view of another example). This shows a configuration in which a U-shaped core is used as a conventional technology, and the height of the coil except for the coil winding portion is increased by using coil wiring that is bent edgewise ((a) is a perspective view of one example, and (b) is a perspective view of another example). 1A and 1B show a configuration in which a U-shaped core is used as a conventional technology and coil wiring is formed by flatwise bending ((a) is a perspective view of one example, and (b) is a perspective view of another example).

<Embodiment>
A boost reactor device according to an embodiment of the present invention will be described below with reference to Figures 1A, 1B, and 2 to 5. The boost reactor device 100 of this embodiment includes a metal case 108 with an open top and made of a material with good thermal conductivity such as metal (aluminum, etc.), a reactor assembly 100A housed therein and mainly made of E-shaped cores 101A, B (see Figure 5(a)) and a coil section 103, and an insulating cooling filler 110 injected between the metal case 108 and the reactor assembly 100A.

<Core>
The boost reactor device 100 according to the embodiment of the present invention includes a pair of E-shaped cores 101A and 101B (see FIG. 5B). The E-shaped cores 101A and 101B are arranged so that the ends of the legs (outer leg cores 101A1 and 101B1, middle leg cores 101A3 and 101B3, and outer leg cores 101A2 and 101B2) protruding at right angles from the base cores 101A4 and 101B4 face each other, forming a square-shaped core section and forming a closed magnetic circuit, as shown in FIG. 5B. In addition, one coil section 103 shown in FIG. 5A is wound around the outer periphery of the butted rod-shaped middle leg cores 101A3 and 101B3, forming a reactor assembly 100A, as shown in FIG. 5C.
As shown in FIG. 5C, resin molded bodies 104A and 104B (integrally molded components of a bobbin and an E-core) described below are attached to the outside of the E-cores 101A and 101B to provide insulation from the coil portion 103.

The core members constituting the E-cores 101A and 101B are made of iron. By using iron, it is possible to realize high magnetic density and to set the degree of coupling, which is easily reduced by this structure, high. As iron-based materials, magnetic steel sheets, powder magnetic cores (pure iron, Fe-Si-Al alloys, Ni-Fe-Mo alloys, Ni-Fe alloys), amorphous, etc. can be used.
The tip ends of the E-shaped cores 101A and 101B may be directly butted against each other, or a spacer may be interposed between the tip ends, or an air gap may be provided.

<Coil section>
The coil portion 103 is formed by winding a rectangular wire edgewise. The rectangular wire is a strip-shaped flat conductor wire as shown in Fig. 1 and generally has a thickness of 0.5 to 6.0 mm and a width of 1.0 to 16.0 mm. The use of a rectangular wire improves the space factor, making it possible to make the device more compact and also providing an advantage in terms of the skin effect .

The coil section 103 is provided for each pair of E-shaped cores 101A, B, and is assembled so as to straddle the butted center core sections 101A3, B3. The coil section 103 is made up of a winding section 103A in which a rectangular wire is wound in sequence into a rectangular shape, and an input end 103B and an output end 103C located at both ends of the winding section 103A. The input and output ends 103B, C at both ends are drawn out vertically from the winding section 103A in parallel with the top surface of the coil.
As shown in FIG. 5(c), the input/output ends 103B, C of the coil section 103 assembled with the E-shaped cores 101A, B have their lower ends passing outward with a small gap between them and the upper surfaces of the resin molded bodies 104A, B corresponding to the E-shaped cores 101A, B, and their tips penetrating the metal case 108, with their wide surfaces connected by welding or the like to external terminals 103D, E, as shown in FIGS. 1A and 1B.

The winding section 103A of the coil section 103 is wound into a cylindrical shape in advance, and when it is stored in the metal case 108, the winding section 103A is inserted into the center leg core sections 101A3, B3 of the E-shaped cores 101A, B to combine with the core, and the input/output ends 103B, C are inserted into the through holes 111B, C of the bracket 108B that engage with the notch section 113 of the case body 108A, and are led out of the case and connected to the external terminals 103D, E.

<Resin Molded Body>
The E-type cores 101A, B are accommodated in a fitted state within resin molded bodies 104A, B (including the bobbin of the coil portion 103 and the covers of the E-type cores 101A, B). The reactor assembly 100A, assembled with the coil portion 103, is set in the metal case 108, and the internal space is filled with a filler 110 made of a fluid resin up to the upper edge of the metal case body 108A, thereby integrating the entire assembly.
The E-shaped cores 101A, B and the coil portion 103 are insulated by the resin molded bodies 104A, B interposed therebetween. Examples of the resin molded body material that can be used include unsaturated polyester resin, urethane resin, epoxy resin, PBT (polybutylene terephthalate), PPS (polyphenylene sulfide), and the above-mentioned resin molded body materials to which glass and thermally conductive fillers are added.
The resin molded bodies 104A, B are formed into a pair of divided structures 104A, B corresponding to the pair of E-shaped cores 101A, B (see FIG. 5C).

<Metal case>
When the pair of E-shaped cores 101A and 101B are butted against each other to form a closed magnetic circuit, one coil portion 103 is attached to the center core portions 101A3 and 101B3 of the E-shaped cores 101A and 101B to form the reactor assembly 100A, and the metal case body 108A is configured to have a height and a planar width sufficient to accommodate the reactor assembly 100A. The metal case body 108A (side wall portion) is formed in a substantially box-like shape with a plate-shaped aluminum standing around the periphery of the bottom plate 109C, and a mounting boss portion 109A having a mounting hole 109B is provided at the lower end of the outer side on all four sides. The shape of the bottom plate 109C corresponds to the outer shape of the reactor assembly 100A, but more specifically, a clearance (for example, about 2 to 4 mm) is provided between the bottom plate 109C and the reactor assembly 100A to the extent that the filler 110 can be filled.

The upper edge of the metal case body 108A (side wall portion) is located higher than the upper surface of the wound portion 103A of the coil portion 103 of the reactor assembly 100A, and is set so that the entire reactor assembly 100A is buried in the filler 110 that will be filled inside later, and is not exposed. The upper edge portion of the case body 108A at the portion through which the input and output ends 103B, C of the coil portion 103 pass is then removed to provide a notch 113 (see FIG. 4) for installing the bracket 108B, and both ends of this notch 113 become edges 114 that engage and hold the bracket 108B.

<Bracket>
The bracket 108B is made of insulating resin. Figures 3 and 4 show the state before and after the bracket 108B is attached to the metal case body 108A. As shown in Figure 1, the bracket 108B has a horizontally long base 107A at the upper part and a horizontal terminal block 107B at the lower end. The end faces at both ends of the base 107A are provided with groove-shaped guides 112 that are engaged and held by edges 114 at both ends of the notch 113 of the metal case body 108A.

In addition, the base portion 107A is configured in a shape folded in two so as to straddle the notch portion 113, thereby improving the effect of preventing the filler 110 from leaking from the metal case .
In addition, on the inside near both ends of the base 107A, a pair of through holes 111B, C are provided through which the input end 103B and the output end 103C of the coil portion 103 are inserted while being in close contact with each other in a vertical orientation. This close contact is set to a degree that the gap formed does not allow the fluid filler 110 filled in the metal case 108 to leak out.

The terminal block 107B is also fitted with L-shaped external terminals 103D, E, the tips of which protrude through the through holes 111B, C to the outside, and are connected and fixed by TIG welding or the like. The horizontal parts of the terminals are laterally engaged and fixed, and the input/output ends 103B, C are connected to the top of the vertical parts.

<Filler>
The metal case 108 is filled with a filler 110 capable of achieving uniform heat distribution in the reactor assembly 108A housed inside the metal case 108. As the filler 110, urethane resin, epoxy resin, acrylic resin, silicone resin, or any of these resin materials to which a thermally conductive filler has been added is used, and the filler is in a liquid or gel-like fluid state when filled, and is solidified by subsequent processing.

In this embodiment, the reactor assembly 100A is configured so that the entirety thereof is immersed in the filler 110, thereby achieving uniform heat distribution.
In addition, the input end 103B and the output end 103C drawn out from the winding portion 103A of the coil portion 103 are also entirely immersed in the filler 110, so that peeling problems that may occur at the interface between the filler 110 and the air when only a portion of the input end 103B and the output end 103C is immersed in the filler 110 can also be prevented.

<Temperature distribution comparison results>
As described above, in the boost reactor device of this embodiment, the entire reactor assembly 100A is configured to be embedded in the filler 110 injected into the metal case 108, thereby achieving the effect of making the temperature distribution uniform.
6A and 6B (comparison to this embodiment) and 7A and 7B (this embodiment) show the results of a simulation conducted to show that the temperature distribution of reactor assemblies 100A', 100A changes significantly when the upper portions of reactor assemblies 100A', 100A are exposed from filler 110 (comparison to this embodiment) and when they are buried in filler 110 (this embodiment).

In addition, FIG. 6A shows, in a comparative example, the temperature distribution of reactor assembly 100A' when a continuous load is applied, and FIG. 6B shows, in a comparative example, the temperature distribution of reactor assembly 100A' when a heavy load is applied for a short period of time (approximately 1 to 30 seconds) after the continuous load is applied.
Similarly, Figure 7A shows the temperature distribution of reactor assembly 100A in this embodiment when a continuous load is applied, and Figure 7B shows the temperature distribution of reactor assembly 100A in this embodiment when a large load is applied for a short period of time (approximately 1 to 30 seconds) after the continuous load is applied.
In each figure, (a) is a cross-sectional front view, (b) is a cross-sectional plan view, and (c) is a cross-sectional side view.

In the comparative example of Figure 6A, as is clear from each of the cross-sectional views (a), (b), and (c), the range of the temperature distribution of 133°C spreads widely from the upper part of coil 103A' at the center, and in the comparative example of Figure 6B, as shown in each of the cross-sectional views (a), (b), and (c), a wide range of the temperature distribution of 150°C can be confirmed.
On the other hand, in the present embodiment of FIGS. 7A and 7B, as is clear from the cross-sectional views (a), (b), and (c), the range of the temperature distribution of 150° C. cannot be confirmed, and it can be confirmed that the range of 133° C. is reduced compared to the comparative examples of FIGS. 6A and 6B. It is clear that the uniformity of the temperature distribution has been greatly improved compared to the above comparative examples.

The specific shapes of the E-cores 101A and 101B in the reactor assembly 100A of the above embodiment can be various shapes as shown in Figures 8(a), (b), and (c). Figures 8(a), (b), and (c) are primarily intended to show the positional relationship between the E-cores 601A, B, 701A, B, and 801A, B and the coils 603, 703, and 803, and therefore omit the aforementioned resin molded bodies such as bobbins.

That is, in the cores 601A and 601B in FIG. 8(a), the heights of the center leg portion 601A3 (601B3 (not shown)), the two outer leg portions 601A1 and 601A2, and the two outer leg portions 601B1 and 601B2, and the base core portions 601A4 and 601B4 connecting these legs are all the same, so the upper surface is formed to be approximately flat.

On the other hand, in the cores 701A and B in FIG. 8(b), the height of the middle leg 701A3 (701B3 (not shown)) and the base core parts 701A4 and 701B4 are the same, but the outer legs 701A1 and 2 and 701B1 and 2 are formed one step lower. In this way, by forming the outer legs 701A1 and 2 and 701B1 and 2 one step lower than the middle leg 701A3 (701B3 (not shown)), it becomes easier to pull out the terminal portion 703B of the coil part 703A.

Furthermore, in cores 801A, B in Figure 8 (c), the heights of center leg portion 801A3 (, 801B3 (not shown)) and both outer leg portions 801A1,2, 801B1,2 are the same, but base core portions 801A3,B3 are formed one step higher. By forming the upper surfaces of cores 801A,B higher so as to increase the volume to the same as the upper surface of coil portion 803A and thinning the longitudinal direction (axial direction of the coil portion), it is possible to form a boost reactor device with similar electrical characteristics even if the longitudinal dimension is reduced to make it more compact while maintaining the same cross-sectional area.
In any of the above embodiments shown in Figures 8(a), (b), and (c), the terminal portions 603B, 703B, and 803B can be pulled out at approximately the same height as the upper surfaces of the coil portions 603A, 703A, and 803A, respectively, thereby making it possible to reduce the height of the device.

The boost reactor device of the present invention is not limited to the above-described embodiment, and various other modifications are possible.
For example, the shape of metal case 108 is not limited to that shown in FIG. 3, and may be any shape capable of accommodating reactor main body 100A.
Furthermore, the shape of bracket 108B of metal case 108 is not limited to the above. For example, in the above embodiment, a pair of small brackets that cover the areas near each of through holes 111B, 111C may be formed to engage with metal case main body 108A.

100 Boost reactor device 100A, 100A' Reactor body (assembly)
101A, B E-type core 101A1, A2, B1, B2 Outer leg core portion 101A3, B3 Center leg core portion 101A4, B4 Base core portion 103 Coil portion 103A Winding portion 103B Input end 103C Output end 103D, E External terminal 104A, B Resin molded body (including bobbin)
107A Base 107B Terminal block 108 Metal case 108A Metal case main body (side wall)
108B bracket 109A mounting boss portion 109B mounting hole 110 filler 111B, C through hole 112 guide portion 113 notch portion 114 edge portion

Claims (5)

a pair of E-shaped cores each having corresponding end faces butted together to form a closed magnetic circuit;
In a state where the pair of E-shaped cores are butted against each other to form a closed magnetic circuit, a coil portion made of a rectangular wire is attached in a wound state to a center leg portion of the pair of E-shaped cores;
a metal case comprising: a metal case body having a height capable of housing the entire assembly obtained by combining the pair of E-shaped cores and the coil section, and having a notch portion on a side wall portion on the side through which the input end and output end of the coil section pass, the notch portion having a depth to allow the input end and output end to pass through; and a bracket that engages with the notch portion, is supported by the metal case body while closing the notch portion, and has a pair of through holes through which the input end and the output end are inserted while being in close contact with each other;
a cooling filler filled in the metal case until the entire assembly is immersed therein ;
A boost reactor device, characterized in that the height of the outer leg portion of the E-shaped core is formed lower than the height of the center leg portion . The boost reactor device according to claim 1, characterized in that the material forming the metal case body is made of aluminum, and the material forming the bracket is made of insulating resin. The boost reactor device according to claim 1 or 2, characterized in that the bracket has an engagement portion with the metal case body, the engagement portion being provided with a groove-shaped guide portion that fits into the edge of the notch in the metal case body. The boost reactor device according to any one of claims 1 to 3, characterized in that the cooling filler is made of a resin having fluidity. The boost reactor device according to any one of claims 1 to 4, characterized in that each of the pair of through holes provided in the bracket is elongated in the height direction of the metal case body so that the rectangular wire can be inserted in an upright state.

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