WO2014073380A1 - Reactor, converter, power conversion apparatus, and reactor manufacturing method - Google Patents

Abstract

Provided are: a reactor having excellent heat dissipating characteristics, insulating characteristics and productivity; a converter that is provided with the reactor; a power conversion apparatus; and a reactor manufacturing method. A reactor (1) is provided with a coil (2) formed by spirally winding a winding wire (2w), and a magnetic core (3) having the coil (2) disposed thereon. The reactor is also provided with a metal member having the coil (2) placed thereon, and a bonding layer (42), which is disposed between the coil (2) and the metal member, and which fixes the coil (2) to the metal member. The bonding layer (42) is configured from a double-sided adhesive sheet (420) which is provided with: an insulating sheet (422) that is configured from an insulating material; and a coil-side adhesive layer (425) in contact with the coil (2), and a metal-side adhesive layer (427) in contact with the metal member, said adhesive layers being formed on the front and rear surfaces of the insulating sheet (422), respectively. The thickness (t_c) of the coil-side adhesive layer (425) is more than the thickness (t_m) of the metal-side adhesive layer (427).

Description

Reactor, converter, power converter, and reactor manufacturing method

The present invention relates to a reactor, a converter including a reactor, a power converter including a converter, and a reactor used in a DC-DC converter mounted on a vehicle such as a hybrid vehicle or a component of a power converter. It relates to a manufacturing method. In particular, the present invention relates to a reactor that is excellent in heat dissipation and insulation properties and also in productivity.

Reactor is one of the circuit components that perform voltage step-up and step-down operations. In Patent Document 1, as a reactor used in a converter mounted on a vehicle such as a hybrid vehicle, a coil including a cylindrical coil element formed by winding a winding in a spiral shape and this coil are arranged. An annular magnetic core and a case that houses a combination of a coil and a magnetic core are disclosed.

Patent Document 1 discloses, in particular, a configuration in which a bottom plate portion of a case on which an assembly is placed and a coil are fixed with an adhesive. By fixing the coil to the metal bottom plate with the adhesive, the heat of the coil that can be generated when using the reactor can be efficiently transmitted to the bottom plate, and as a result, the heat of the coil can be transferred to the installation target to which the reactor is attached. . Therefore, this reactor is excellent in heat dissipation.

Japanese Patent No. 4959633

Development of a reactor that excels in heat dissipation and insulation as well as productivity is desired.

The reactor described in Patent Document 1 is excellent in heat dissipation as described above by including an adhesive layer made of an adhesive. Further, for example, when the adhesive layer between the coil and the metal bottom plate portion has a multilayer structure, the insulating property can be enhanced. However, when the number of layers is increased, a curing process is required for each layer, resulting in a decrease in productivity.

When using one sheet-like adhesive described in Patent Document 1, the curing process can be performed once. Moreover, even if it is one sheet-like adhesive, insulation can be improved if thickness is increased. However, when the thickness is increased, the curing time becomes longer and the productivity is lowered. Moreover, since the reactor is increased in size by increasing the thickness, there is a limit to the improvement in insulation by increasing the thickness of the sheet-like adhesive. Furthermore, since the distance between a coil and a baseplate part becomes large by making the said thickness thick, the fall of heat dissipation is caused depending on the material.

Therefore, it is desired to develop a structure that is excellent in heat dissipation and productivity even when the insulation is further improved.

Therefore, one of the objects of the present invention is to provide a reactor that is excellent in heat dissipation and insulation properties and also in productivity. Another object of the present invention is to provide a converter including the reactor and a power conversion device including the converter. Furthermore, another object of the present invention is to provide a reactor manufacturing method capable of manufacturing a reactor excellent in heat dissipation and insulation with high productivity.

The reactor of the present invention is a reactor comprising a coil formed by winding a winding in a spiral shape, and a magnetic core on which the coil is disposed, and a metal member on which the coil is placed, and the coil And a bonding layer that is interposed between the metal member and fixes the coil to the metal member. The bonding layer includes both an insulating sheet made of an insulating material, a coil-side adhesive layer that contacts the coil, and a metal-side adhesive layer that contacts the metal member. It consists of an adhesive sheet. The coil side adhesive layer is thicker than the metal side adhesive layer.

The method for manufacturing a reactor according to the present invention relates to a method for manufacturing a reactor by assembling a coil formed by winding a winding in a spiral and a magnetic core on which the coil is arranged, and includes the following steps. Yeah.
A step of preparing a double-sided adhesive sheet comprising an insulating sheet made of an insulating material and adhesive layers respectively formed on the front and back surfaces of the insulating sheet.
The process of arrange | positioning the said double-sided adhesive sheet in the metal member in which the assembly of the said coil and the said magnetic core is mounted.
Placing the assembly on the double-sided adhesive sheet;
Curing the adhesive layer provided on the double-sided adhesive sheet and joining the coil and the metal member via the double-sided adhesive sheet;
In the double-sided adhesive sheet, the thickness of one adhesive layer in contact with the coil is thicker than the thickness of the other adhesive layer in contact with the metal member.

The reactor of the present invention is excellent in heat dissipation and insulation, and also in productivity. The reactor manufacturing method of the present invention can manufacture a reactor excellent in heat dissipation and insulation with high productivity.

It is a schematic perspective view which shows the reactor of Embodiment 1. FIG. It is a disassembled perspective view which shows the outline of the reactor of Embodiment 1. FIG. It is a disassembled perspective view which shows the outline of the assembly of the coil and magnetic core which are provided in the reactor of Embodiment 1. FIG. (A) is a partial cross-sectional view showing a (IV)-(IV) cross section in the reactor shown in FIG. 1, (B) is an enlarged cross-sectional view in a broken line region in FIG. 4 (A), and (C) is a double-sided adhesive tape. It is sectional drawing. 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit diagram which shows an example of the power converter device of Embodiment 4 which provides the converter of Embodiment 4.

[Description of Embodiment of the Present Invention]
The present invention achieves the above-mentioned object by providing a bonding layer composed of a specific adhesive sheet. First, the contents of the embodiment of the present invention will be listed and described.

(1) The reactor according to the embodiment includes a coil formed by winding a winding in a spiral shape, a magnetic core on which the coil is disposed, a metal member on which the coil is placed, and the coil And a joining layer that is interposed between the metal member and fixes the coil to the metal member. The bonding layer includes both an insulating sheet made of an insulating material, a coil side adhesive layer formed on the front and back surfaces of the insulating sheet and in contact with the coil, and a metal side adhesive layer in contact with the metal member. It consists of an adhesive sheet. And the thickness of the said coil side contact bonding layer is thicker than the thickness of the said metal side contact bonding layer.

In the reactor of the embodiment, a metal member (for example, a metal plate or a bottom plate portion of a case) generally made of a metal having excellent thermal conductivity and a coil are joined by a joining layer, so that the metal member is a heat dissipation member. The heat of the coil can be efficiently transmitted to the outside (for example, the installation target of the reactor). Therefore, the reactor of the embodiment is excellent in heat dissipation.

In the reactor of the embodiment, an insulating sheet which is a part of the bonding layer is interposed between the coil and the metal member, and the insulating sheet functions as an insulating member to insulate the coil from the metal member. Increases sex. Therefore, the reactor according to the embodiment is excellent in insulation even if the bonding layer is thin. Specifically, the reactor according to the embodiment can ensure equivalent or higher insulation as compared with a case where a thick adhesive layer made of a single material adhesive is interposed between the coil and the metal member. Moreover, the reactor of embodiment can shorten the distance between a coil and a metal member by thickness reduction of a joining layer. Also from this point, the reactor of embodiment is excellent in heat dissipation.

Furthermore, the reactor according to the embodiment uses a double-sided adhesive sheet as a constituent member of the bonding layer, so that a single curing step is required when fixing the coil and the metal member, and the productivity is excellent. Moreover, when the bonding layer (double-sided adhesive sheet) is thinned as described above, the curing time can also be shortened. Also from this point, the reactor of embodiment is excellent in productivity.

In addition, since the thickness of the coil-side adhesive layer is larger than that of the metal-side adhesive layer, the reactor according to the embodiment has an inevitable variation in the outer shape of the turn that can be caused by winding the winding spirally. Can be absorbed by layer. That is, each of the turns in the coil and the constituent material of the coil-side adhesive layer can be sufficiently contacted, and the coil and the metal member are firmly bonded. Also from this point, the reactor of embodiment is excellent in heat dissipation. Moreover, it can also be set as the reactor which is excellent in shape precision and dimensional precision by absorption of the above-mentioned dispersion | variation.

(2) As an example of the reactor according to the embodiment, a form in which the thickness of the coil side adhesive layer is more than 30 μm and not more than 350 μm can be given.

The above-mentioned form in which the thickness of the coil-side adhesive layer is in the above-mentioned range is that the coil and the metal member are firmly joined, and further, the heat dissipation is deteriorated and the reactor is enlarged due to excessive thickness of the adhesive layer. Can be suppressed. Therefore, the said form can be made into a small reactor while being excellent in heat dissipation.

(3) As an example of the reactor according to the embodiment, there is a form in which an adhesive constituting the coil side adhesive layer is interposed between adjacent turns in the coil.

Since the adhesive is interposed between the turns, the contact area between each turn and the adhesive is large, and the coil and the metal member are more firmly bonded. Therefore, the said form is more excellent by heat dissipation.

(4) As an example of the reactor according to the embodiment, a form in which the winding includes a conductor composed of a rectangular wire, and the coil is an edgewise coil.

The edgewise coil is easy to increase the space factor and can be a small coil. In particular, in the above-described configuration in which an adhesive is interposed between the turns, the coil and the metal member are further firmly bonded by the anchor effect of the adhesive interposed between the turns. Therefore, the said form is further excellent in heat dissipation while being small.

As an example of the reactor according to the embodiment, it further includes a case that houses a combination of the coil and the magnetic core, and the case is independent of the bottom plate portion on which the combination is placed and the bottom plate portion. It can be made into the form which comprises the side wall part which is the member which encloses the circumference | surroundings of the said assembly. In this embodiment, it is preferable that the metal member is the bottom plate portion and the side wall portion is made of an insulating resin.

In the above embodiment, the double-sided adhesive sheet constituting the assembly and the bonding layer can be placed on the bottom plate part with the side wall part removed, and the assembly workability is excellent. Moreover, the said form can improve the insulation of a coil and a baseplate part by a double-sided adhesive sheet (especially insulating sheet), and when a coil and a side wall part are made to adjoin by the side wall part comprised with insulating resin. However, insulation between the coil and the side wall can be ensured. Therefore, the said form is excellent in productivity, and also is excellent in the insulation between a coil and a case. Furthermore, the said form is excellent also in heat dissipation by making a part (bottom plate part) of a case function as a heat radiating member.

The reactor which concerns on the above-mentioned embodiment can be utilized suitably for the component of a converter.
(5) The converter according to the embodiment includes the reactor according to the embodiment described in any one of (1) to (4) above.

The converter of the embodiment is excellent in heat dissipation, insulation, and productivity by including the reactor of the embodiment excellent in heat dissipation, insulation, and productivity.

The converter of the said embodiment can be utilized suitably for the component of a power converter device.
(6) The power converter device which concerns on embodiment comprises the converter of the said embodiment.

The power conversion device of the embodiment is excellent in heat dissipation, insulation, and productivity by including the converter of the embodiment including the reactor of the embodiment that is excellent in heat dissipation, insulation, and productivity.

The reactor which concerns on the above-mentioned embodiment can be manufactured with the following manufacturing methods, for example. (7) A method for manufacturing a reactor according to the embodiment relates to a method for manufacturing a reactor by assembling a coil formed by winding a winding spirally and a magnetic core on which the coil is arranged, and Preparation step, sheet placement step, assembly placement step, and joining step.
(Preparation process) The process of preparing the double-sided adhesive sheet which comprises the insulating sheet comprised from the insulating material, and the contact bonding layer formed in the front and back of the said insulating sheet, respectively.
(Sheet Arrangement Step) A step of arranging the double-sided adhesive sheet on a metal member on which an assembly of the coil and the magnetic core is placed.
(Union body mounting process) The process of mounting the said assembly body on the said double-sided adhesive sheet.
(Jointing step) A step of curing the adhesive layer provided on the double-sided adhesive sheet and joining the coil and the metal member via the double-sided adhesive sheet.
In the double-sided adhesive sheet, the thickness of one adhesive layer in contact with the coil is thicker than the thickness of the other adhesive layer in contact with the metal member.

The manufacturing method of the reactor of the embodiment uses a double-sided adhesive sheet for joining the coil and the metal member, so that the constituent material of the joining layer is cured from the placement of the constituent material on the metal member to the joining of the coil and the metal member. The process can be performed once. Therefore, the manufacturing method of the reactor of embodiment can manufacture the reactor of embodiment which is excellent in the heat dissipation and insulation mentioned above with sufficient productivity.

Moreover, as a double-sided adhesive sheet, by using a thin one adhesive layer (the above-mentioned metal side adhesive layer), compared to the case where both adhesive layers have the same thickness and are thick. A reactor having a short distance between the coil and the metal member can be manufactured. In particular, by curing the adhesive constituting the adhesive layer in a state where the combination of the coil and the magnetic core is placed on the above-described specific double-sided adhesive sheet, the thickness of both adhesive layers is increased by this curing. Can be thin. Here, when the multilayer adhesive layer is formed by performing the curing for each layer, the outermost layer in contact with the combined body of the multilayer adhesive layers is arranged in an uncured state, and then Cured. For this reason, the thickness of the outermost layer after curing tends to be thinner than that before curing by being pressed by the combination. However, since the adhesive layer below the outermost layer is already cured, the thickness of the lower adhesive layer does not substantially change after the outermost layer is cured. In other words, it does not become thin. Therefore, the reactor manufacturing method of the embodiment using the double-sided adhesive sheet in which the thickness of the adhesive layer has a specific relationship is compared with the case where a multilayer adhesive layer is constructed by curing each layer. A reactor having a shorter distance between the metal member and the metal member can be manufactured. Also from this point, the manufacturing method of the reactor of embodiment can manufacture the reactor excellent in heat dissipation. Moreover, the manufacturing method of the reactor of embodiment can manufacture a small reactor because the distance between a coil and a metal member is short.

[Details of the embodiment of the present invention]
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The same reference numerals in the figure indicate the same names.

[Embodiment 1]
The reactor according to the first embodiment will be described with reference to FIGS.

(Reactor overall configuration)
As shown in FIG. 1, the reactor 1 includes a coil 2 formed by spirally winding a winding 2 w and a magnetic core 3 on which the coil 2 is disposed. Furthermore, the reactor 1 of this example also includes a case 4 that houses an assembly 10 of a coil 2 and a magnetic core 3. The case 4 includes a bottom plate portion 40 (FIG. 2) on which the combined body 10 is placed and a side wall portion 41 standing from the bottom plate portion 40. The bottom plate part 40 is a metal member made of a metal material. The coil 2 is fixed to the bottom plate portion 40 by a bonding layer 42 (FIG. 2) interposed between the coil 2 and the bottom plate portion 40. A feature of the reactor 1 of the first embodiment is that the bonding layer 42 is formed of a double-sided adhesive sheet having a specific three-layer structure. Hereinafter, the outline of the coil 2 and the magnetic core 3 that are the main constituent members of the reactor 1, the outline of the case 4 that houses them, the bonding layer 42 that is a characteristic point (double-sided adhesive sheet 420, FIG. 4C), the reactor First, the main effects based on the manufacturing method and feature points will be described first, and then each configuration will be described in detail.

(Outline of coil and magnetic core)
Both the coil 2 and the magnetic core 3 can be of a known shape and material. Here, as shown in FIGS. 2 and 3, the coil 2 includes a pair of coil elements 2a and 2b formed by spirally winding a winding 2w, and a connecting portion 2r for connecting both the coil elements 2a and 2b. With Each coil element 2a, 2b is a hollow cylindrical body having the same number of turns, and is arranged in parallel (side by side) so that the respective axial directions are parallel. Here, the winding 2 w is a covered rectangular wire including a conductor made of a copper rectangular wire and an insulating coating covering the surface of the conductor. Each of the coil elements 2a and 2b is an edgewise coil in which the covered rectangular wire is wound edgewise.

Here, the magnetic core 3 includes a pair of columnar inner core portions 31 and a pair of columnar outer core portions 32 as shown in FIG. Each inner core portion 31 is inserted and arranged in the coil elements 2a and 2b arranged side by side, and is used as a coil arrangement portion. The outer core portion 32 is a portion that is exposed from the coil 2 and is not substantially disposed. Each outer core part 32 is arrange | positioned so that both the inner core parts 31 arranged side by side may be connected, and the cyclic | annular magnetic core 3 is formed.

(Case outline)
As shown in FIG. 2, the case 4 is a member in which the bottom plate portion 40 constituting the bottom portion of the case 4 and the side wall portion 41 constituting the wall portion of the case 4 are independent in the manufacturing process of the reactor 1. In the completed state of the reactor 1, as shown in FIG. 1, the bottom plate part 40 and the side wall part 41 are assembled by a fixing member (not shown) and formed in a box shape.

The bottom plate portion 40 on which the assembly 10 is placed is a metal member as described above, and functions as a heat radiating member that transfers the heat of the coil 2 to the outside. In the completed state of the reactor 1, the bonding layer 42 is interposed between the region facing the bottom plate portion 40 (the lower surface in FIGS. 2 and 4A) of the coil 2 and the inner surface 40 i of the bottom plate portion 40. And the bottom plate part 40 are joined by the joining layer 42 (FIG. 4A). In FIG. 4A, only the vicinity of the bottom plate portion 40 is shown for easy understanding. 4A and 4B, the coil 2 (winding 2w) is not hatched for easy understanding. FIG. 4B shows an enlarged view of a region surrounded by a dotted line in FIG.

(Bonding layer)
As shown in FIG. 4B, the bonding layer 42 has a three-layer structure including an insulating sheet 422 made of an insulating material and adhesive layers 425 and 427 formed on the front and back surfaces of the insulating sheet 422, respectively. .

The insulating sheet 422 is a flat plate-like member for enhancing electrical insulation between the coil 2 and the metal member (here, the bottom plate portion 40). Therefore, the insulating sheet 422 has a predetermined withstand voltage characteristic. For example, in a vehicle-mounted reactor, an insulating sheet 422 having a withstand voltage characteristic of 1 kV or more, and further 3 kV or more is preferable. For example, in the case of a sheet material having 10 kV / mm or more, the insulating sheet 422 having a desired withstand voltage characteristic (kV) can be obtained by adjusting the thickness. Further, when the insulating sheet 422 is made of a material having high thermal conductivity, it is preferable because heat dissipation is improved. For example, thermal conductivity is 0.1 W / m · K or more, further 0.15 W / m · K or more, 0.5 W / m · K or more, 1 W / m · K or more, or 2.0 W / m · K or more The insulating sheet 422 that satisfies the requirements can improve heat dissipation.

Specific examples of the material for the insulating sheet 422 include polyimide resin, amideimide resin, polyester resin, and epoxy resin. A polyimide resin is excellent in heat resistance and insulation. Amidoimide resins have very high heat resistance. Epoxy resin is excellent in insulation. Although depending on the dielectric breakdown strength (kV / mm) and thickness, these resins can have a withstand voltage characteristic of about 5 kV to 7 kV, for example, when the thickness is 50 μm. Other materials include, for example, ceramics such as silicon nitride (Si ₃ N ₄ ), alumina (Al ₂ O ₃ ), aluminum nitride (AlN), boron nitride (BN), silicon carbide (SiC), etc. The thing containing the filler which consists of is mentioned. The insulating sheet 422 made of a resin containing a filler made of the ceramic can further improve heat dissipation and insulation.

The thickness t _i of the insulating sheet 422 can be appropriately selected as long as the desired withstand voltage characteristics are satisfied as described above. The thickness _{t i} of the insulating sheet 422, depending on the material, if it is 10μm or more 100μm or less, can be made thin bonding layer 42 on which is excellent in insulating properties. Since the joining layer 42 is thin, the distance between the coil 2 and the metal member (here, the bottom plate portion 40) can be shortened, and the reactor 1 is excellent in heat dissipation. In particular, when the insulating sheet 422 is made of a material having excellent insulating properties (for example, when the withstand voltage characteristic satisfies 7 kV or more), even if the insulating sheet 422 is thin (for example, 10 μm or more and 50 μm or less, further 30 μm or less), Excellent insulation. In addition, since the insulating sheet 422 is thin as described above, the bonding layer 42 is thinned, and as a result, the distance between the coil 2 and the metal member (here, the bottom plate portion 40) can be shortened, and the heat dissipation is further improved. When the insulating sheet 422 is made of a material having excellent thermal conductivity (for example, when the thermal conductivity satisfies 0.5 W / m · K or more), the heat dissipation is excellent even if the insulating sheet 422 is made thick within the above range.

The adhesive layers 425 and 427 provided on the front and back surfaces of the flat insulating sheet 422 are bonded between the coil 2 and the insulating sheet 422, and bonded between the insulating sheet 422 and the metal member (here, the bottom plate portion 40), respectively. Used for The materials of the constituent materials of the former adhesive layer = coil side adhesive layer 425 and the latter adhesive layer = metal side adhesive layer 427 can be joined as described above, and have heat resistance against the ultimate temperature when the reactor 1 is used. Things are available. Specific materials include thermosetting resins such as epoxy resins, silicone resins, and unsaturated polyesters, and thermoplastic resins such as acrylic resins, polyphenylene sulfide (PPS) resins, and liquid crystal polymers (LCP). The materials of both layers 425 and 427 can be the same or different.

The above-mentioned resin is applied to the front and back surfaces of the insulating sheet 422, and then cured to some extent, thereby producing a double-layer adhesive sheet 420 having a three-layer structure in which the insulating sheet 422 is held between the two adhesive layers 425 and 427. Yes (FIG. 4C). The bonding layer 42 is formed by completely curing the double-sided adhesive sheet 420 having a three-layer structure.

In the bonding layer 42, the thickness t _c of the coil side adhesive layer 425 and the thickness t _m of the metal side adhesive layer 427 are different. Specifically, the thickness t _c of the coil side adhesive layer 425 is thicker than the thickness t _m of the metal side adhesive layer 427. Note that the thickness t _c of the coil side adhesive layer 425 and the thickness t _m of the metal side adhesive layer 427 in the bonding layer 42 are the thicknesses of the adhesive layers 425 and 427 completely cured.

Since the thickness t _c of the coil side adhesive layer 425 that joins the coil 2 and the insulating sheet 422 is relatively thick, the contact area with the coil 2 is increased, the variation in the outer shape of the turn in the coil 2 is absorbed, and the insulating property. Can be improved. Since the thickness t _m of the metal-side adhesive layer 427 that joins the insulating sheet 422 and the metal member (here, the bottom plate portion 40) is relatively thin, the joining layer 42 becomes thin, and consequently the reactor 1 is downsized. be able to. Such a bonding layer 42 is formed by using a double-sided adhesive sheet 420 in which the thickness t _cs of the coil side adhesive layer 425 is thicker than the thickness t _ms of the metal side adhesive layer 427 as shown in FIG. can do. Note that the thickness t _cs of the coil side adhesive layer 425 and the thickness t _ms of the metal side adhesive layer 427 in the double-sided adhesive sheet 420 are the thicknesses before the adhesive layers 425 and 427 are completely cured (typically Is the thickness when the coil 2 and the metal member are not arranged and are in an independent state.

A specific thickness t _c of the coil side adhesive layer 425 in the bonding layer 42 is, for example, more than 30 μm and 350 μm or less. When the thickness t _c of the coil side adhesive layer 425 is 350 μm (0.35 mm) or less, the bonding layer 42 is sufficiently thin, and heat dissipation can be improved and the size can be reduced. Since the thickness t _c of the coil side adhesive layer 425 is more than 30 μm, the thickness t _cs of the double-sided adhesive sheet 420 before being completely cured also has a sufficient thickness, and the contact area described above Increase, variation absorption, and insulation can be improved. When the thickness t _c of the coil side adhesive layer 425 is 300 μm or less, 200 μm or less, and further less than 100 μm, the bonding layer 42 is further thinned, and when the thickness t _c is 50 μm or more, and further 100 μm or more, the insulating property is improved. Further enhanced. Therefore, it is considered that the thickness t _c of the coil side adhesive layer 425 is preferably about 70 μm or more and 120 μm or less. Here, the thickness t _c of the coil-side adhesive layer 425 in the bonding layer 42 is the average thickness between the surface of the coil 2 facing the bottom plate portion 40 and one surface of the insulating sheet 422 (FIG. 4B). .

The thickness t _cs of the double-sided adhesive sheet 420 may be adjusted so that the thickness t _c of the coil-side adhesive layer 425 in the bonding layer 42 becomes a desired thickness. For example, the thickness t _cs of the coil side adhesive layer 425 included in the double-sided adhesive sheet 420 may be 50 μm or more and 500 μm or less.

Specific thickness t _m of the metal side adhesive layer 427 in the bonding layer 42 is, for example, 5 μm or more and 50 μm or less (where t _c > t _m ). When the thickness t _m of the metal-side adhesive layer 427 satisfies the above range, the insulating sheet 422 and the metal member (here, the bottom plate portion 40) can be sufficiently bonded, and the bonding layer 42 is thin, so that heat dissipation is achieved. Improvement and downsizing can be achieved. The thickness t _m of the metal side adhesive layer 427 can be set to 20 μm or more.

The thickness t _ms of the double-sided adhesive sheet 420 may be adjusted so that the thickness t _m of the metal side adhesive layer 427 in the bonding layer 42 becomes a desired thickness. For example, the thickness t _ms of the metal side adhesive layer 427 provided in the double-sided adhesive sheet 420 may be more than 5 μm and not more than 100 μm.

In addition, in the state which mounted the union body 10, both the adhesive layers 425 and 427 of the double-sided adhesive sheet 420 are hardened simultaneously, and the union body 10 and the metal member (here, the bottom plate part 40) are joined, thereby the union body 10 Than the thickness t _cs and t _ms when only the double-sided adhesive sheet 420 is placed, the thickness t _c and t _m at the time of the reactor 1 are usually set by pressing the union 10 by its own weight. It becomes thinner (t _c <t _cs , t _m <t _ms ). However, the above-described thickness relationship (the thickness of the coil-side adhesive layer 425 is greater than the thickness of the metal-side adhesive layer 427) is maintained even after the above-described curing. In addition, the thickness tis of the insulating sheet 422 when only the double-sided adhesive sheet 420 _{is used} may be thinned by pressing or the like due to the weight of the combined body 10 (t _i ≦ t _is ).

The ratio (t _c / t _m ) of the thickness t _c of the coil side adhesive layer 425 to the thickness t _m of the metal side adhesive layer 427 in the bonding layer 42 can be appropriately selected. Is mentioned. The ratio of the thickness t _cs of the coil side adhesive layer 425 to the thickness t _ms of the metal side adhesive layer 427 in the double-sided adhesive tape 420 (t _cs / t _ms ), the curing conditions, etc. It is good to adjust. If the thickness ratio (t _cs / t _ms ) in the double-sided adhesive tape 420 is too large, the coil side adhesive layer 425 is too thick, leading to a thickening of the bonding layer 42, or the coil side adhesive layer 425 and the metal side. Since there is a risk of warping based on the difference in thermal expansion and contraction with the adhesive layer 427, it is preferably about 10 or less, and more preferably about 2 or more and 5 or less. The thickness ratio (t _c / t _m ) in the bonding layer 42 may substantially maintain the thickness ratio (t _cs / t _ms ) in the double-sided adhesive tape 420, but as will be described later, In the case where the adhesive constituting the adhesive layer 425 is interposed between turns, the thickness t _c of the bonding layer 42 is small, so that t _c / t _m ≠ t _cs / t _ms may be satisfied.

From the above, the thickness t (= t _i + t _c + t _m ) of the bonding layer 42 is more than 45 μm and not more than 500 μm, preferably not more than 200 μm, and the thickness t _s (= t _is + t _cs ) of the double-sided adhesive sheet 420. + T _ms ) is about 65 μm or more and 700 μm or less, preferably about 500 μm or less.

The bonding layer 42 and the double-sided adhesive sheet 420 have an area where at least a surface facing the metal member (here, the bottom plate portion 40) of the coil 2 (here, a virtual surface formed by a plurality of turns) can be sufficiently contacted. If it is, shape and size are not particularly limited. Here, as shown in FIG. 2, the bonding layer 42 and the double-sided adhesive sheet 420 are surfaces facing the metal member in the assembly 10 (here, the virtual surface of the coil 2 and the metal member side of the outer core portion 32. The shape is in line with the contour created by the surface. Therefore, since both the coil 2 and the outer core part 32 can fully contact the joining layer 42 and both heats are transmitted to the outside through the metal member, the reactor 1 can further improve heat dissipation.

Here, the bonding layer 42 and the insulating sheet 422 of the double-sided adhesive sheet 420 are made of polyimide, and the adhesive layers 425 and 427 are made of epoxy resin. Further, here, the thickness _{t IS} is 25μm insulating sheet 422, the thickness _{t cs} is 300μm coil side adhesive layer 425, a double-sided adhesive sheet 420 having a thickness of _{t ms} is 30μm metal side adhesive layer 427 using the bonding The thickness t _i of the insulating sheet 422 in the layer 42 is 25 μm, the thickness t _c of the coil side adhesive layer 425 is 100 μm, and the thickness t _m of the metal side adhesive layer 427 is 10 μm (t _c / t _m = 10). is there.

(Reactor manufacturing method)
The reactor 1 can be manufactured through the following steps (1) to (4), for example.

(1) In the preparation step, a double-sided adhesive sheet 420 is prepared.
In this step, the above-mentioned specific three-layer structure double-sided adhesive sheet 420 is prepared. As described above, the adhesive layers 425 and 427 are formed on the front and back surfaces of the insulating sheet 422 so that the thickness t _cs of the coil side adhesive layer 425 is larger than the thickness t _ms of the metal side adhesive layer 427. Further, the double-sided adhesive sheet 420 is cut into a desired shape.

(2) In the sheet arranging step, the double-sided adhesive sheet 420 is arranged on the metal member.
In this step, the prepared double-sided adhesive sheet 420 is placed on a metal member (here, the bottom plate portion 40). Here, since the bottom plate portion 40 and the side wall portion 41 are independent as described above, the double-sided adhesive sheet 420 can be disposed on the bottom plate portion 40 with the side wall portion 41 removed, and the workability is excellent.

(3) In the combined body mounting step, the combined body 10 is mounted on the double-sided adhesive sheet 420.
In this step, the combined body 10 is prepared in advance, and the combined body 10 is placed on the double-sided adhesive sheet 420. Here, as shown in FIG. 3, the combined body 10 is formed by stacking a plurality of core pieces 31m and a gap material 31g to form two inner core portions 31, and the inner core portions 31 are respectively coiled elements 2a and 2b. It can manufacture by assembling | attaching so that the end surface 31e of both the inner core parts 31 and the inner end surface 32 of the outer core part 32 may contact | connect, after arrange | positioning inside. The higher the mounting step, since the adhesive layer 425, 427 made somewhat thinned by imposition of its own weight or below of the combined product 10, the thickness t _s of the double-sided adhesive sheet 420 is somewhat thinner.

(4) In the joining step, the adhesive layers 425 and 427 provided on the double-sided adhesive sheet 420 are cured, and the coil 2 and the metal member are joined by the double-sided adhesive sheet 420.
In this step, the double-sided adhesive sheet 420 is brought to a predetermined temperature, so that both the adhesive layers 425 and 427 are softened to some extent, and the coil 2 and the insulating sheet 422 are joined by the coil-side adhesive layer 425, and the metal-side adhesive layer The insulating sheet 422 and the metal member (here, the bottom plate portion 40) can be joined by 427, and then cured to fix the joined state. As a result, the coil 2 and the metal member are joined by the double-sided adhesive sheet 420.

In addition, the coil 2, the magnetic core 3, and the metal member (here, the bottom plate portion 40) are provided by the step (4), and the coil 2 and the metal member are configured by curing the double-sided adhesive sheet 420. The reactor 1 bonded through the bonding layer 42 is obtained.

Furthermore, as shown in FIG. 4B, the reactor 1 can have a form in which an adhesive constituting the coil-side adhesive layer 425 is interposed between adjacent turns in the coil 2. In this form, the contact between the coil 2 and the adhesive is mainly compared to the case where the adhesive is mainly in contact with the surface (the virtual surface described above) facing the metal member (here, the bottom plate portion 40) in the coil 2. The area increases. Therefore, in this embodiment, the heat of the coil 2 is easily transmitted by the metal member, the heat dissipation is excellent, and the coil 2 is firmly fixed by the metal member. Further, the adhesive constituting the coil side adhesive layer 425 included in the double-sided adhesive sheet 420 is cured in a state of being interposed between the turns, so that the thickness t _c of the coil side adhesive layer 425 in the bonding layer 42 is further increased. Can be thinned efficiently. Also from this point, this form is excellent in heat dissipation. In particular, when an edgewise coil is used as in this example, stronger anchoring can be realized by an anchor effect due to the presence of an adhesive as compared to a flatwise coil or a coil using a round wire.

In the above embodiment, when the distance between adjacent turns is narrowed, specifically, when it is 0.3 mm or less, and further 0.2 mm or less, the axial length of the coil 2 does not become too long, and the coil 2 and the metal member The adhesive constituting the coil-side adhesive layer 425 can be sufficiently interposed between (the bottom plate portion 40 here) and is preferable. The coil 2 is formed so that the adjacent turns have a desired interval. Further, by narrowing the distance between adjacent turns as described above, the adhesive before curing can penetrate to some extent by capillary action, although it depends on the viscosity of the adhesive before curing. Furthermore, by pressing the combined body 10 against the double-sided adhesive sheet 420 side with a jig or the like when the above-mentioned curing is performed, the penetration depth of the adhesive before the curing can be further increased, and the adjacent turn It is possible to uniformly penetrate between them. As a result, it is possible to penetrate the height h _i is larger reactor adhesive interposed between adjacent turns.

Penetration height h _i can be appropriately selected. For example, if the coil 2 is an edgewise coil, penetration height _{h i} is 1 / 4-1 / 2 of about the width W of the windings 2w (flat wire) (0.25 × W or 0.5 × W The contact area is sufficiently large, and the thickness t _c of the coil side adhesive layer 425 can be sufficiently secured. It is preferable to adjust the interval between turns, the pressing force, and the like so that the penetration height _hi becomes a desired height.

The manufacturing of the reactor 1 shown in FIG. 1 further includes a step of assembling the case 4 by assembling the bottom plate portion 40 and the side wall portion 41.
Here, the side wall 41 is placed on the bottom plate 40 by covering the side wall 41 from above the combination 10 so as to surround the outer peripheral surface of the combination 10 fixed by the bonding layer 42. Then, the bottom plate portion 40 and the side wall portion 41 are integrated by a fixing member (a connecting bolt not shown here). By this step, the reactor 1 in which the combined body 10 is housed in the case 4 is obtained.

(Main effect)
The reactor 1 is excellent in heat dissipation from the following points.
(1) Since the coil 2 and the metal member (here, the bottom plate portion 40) are joined by the joining layer 42, even if the coil or the like generates heat during use, this heat can be efficiently transferred to the outside (such as the installation target of the reactor 1). ).
(2) Since the bonding layer 42 includes the insulating sheet 422 and is excellent in insulation, the bonding layer 42 can be thinned, and the distance between the coil 2 and the metal member can be shortened.
(3) Since the coil-side adhesive layer 425 in the bonding layer 42 is thick, the coil 2 can sufficiently contact.

(4) By using the specific double-sided adhesive sheet 420, both the adhesive layers 425 and 427 in the bonding layer 42 can be made thin, and the distance between the coil 2 and the metal member can be made shorter.
For example, formation of the first adhesive layer on the metal member (here, the bottom plate portion 40) → placement of the insulating sheet → curing of the first adhesive layer → formation of the second adhesive layer on the insulating sheet → combination Consider the case where the second adhesive layer is cured in this order. In this case, the second adhesive layer can be made thinner than before curing by the weight of the assembly or pressing. However, since the assembly is placed after the first adhesive layer is cured, the first adhesive layer is unlikely to be thin. On the other hand, in the reactor 1, both the adhesive layers 425 and 427 can be made thinner than before curing by the weight or pressing of the combined body 10, so that the coil 2 and the metal member can be used rather than the above-described two times of curing. The distance between can be shortened.

And the reactor 1 is excellent also in insulation from the point in which the joining layer 42 comprises the insulating sheet 422. Moreover, the reactor 1 can aim at reduction of a hardening process and shortening of hardening time by comprising the joining layer 42 with the specific double-sided adhesive sheet 420, and it is excellent also in productivity. Furthermore, the reactor 1 can absorb the dispersion | variation in the shape of the coil 2 because the coil side contact bonding layer 425 in the joining layer 42 is thick, and is excellent also in shape precision and dimensional accuracy.

Hereinafter, the detail of each component of the reactor 1 is demonstrated.
(coil)
As shown in FIGS. 2 and 3, the coil 2 is formed by a single continuous winding 2 w. More specifically, a part of the winding 2w extending from the end of one coil element 2a is bent in a U shape to form a connecting part 2r, and the other coil element 2b is subsequently connected to the connecting part 2r. Is formed. With this configuration, the winding directions of both coil elements 2a and 2b are the same, and both coil elements 2a and 2b are electrically connected in series. Here, the end face shape of the coil elements 2a and 2b is a rectangular shape with rounded corners, but may be appropriately changed such as an annular shape.

Each coil element is manufactured by separate windings, and one end of each coil element winding is directly joined by welding, soldering, crimping, etc., or via a separately prepared connecting member (for example, plate material). It can also be a coil joined.

As the winding 2w, a coated wire having an insulating coating made of an insulating material (typically polyamideimide) on the outer circumference of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof can be suitably used. The conductor is typically a round wire or a rectangular wire. As in this example, when an edgewise coil is formed by using a (covered) flat wire for the winding 2w, (1) it is easy to form a coil having a higher space factor than when a round wire is used. (2) Since at least a part of the outer peripheral surface (virtual surface) formed by a plurality of turns can be made flat, it is possible to secure a wide contact area with the bonding layer 42 and improve heat dissipation. (3) Winding There is an advantage that a wide contact area can be secured between the wire 2w and a connection object such as a terminal fitting 8 (described later).

At both ends of the winding 2 w forming the coil 2, the terminal fitting 8 is typically connected to the conductor portion exposed by peeling off the insulation coating. An external device (not shown) such as a power source for supplying power is connected to the coil 2 via the terminal fitting 8. It may be directly connected to the connection location of the external device without going through the terminal fitting 8. The winding 2w and the terminal fitting 8 may be joined at an appropriate time. In this example, it may be performed after the case 4 is assembled.

(Magnetic core)
As shown in FIG. 3, the inner core portion 31 of the magnetic core 3 includes a plurality of core pieces 31m made of a soft magnetic material and gap members 31g made of a material having a relative permeability smaller than that of the core pieces 31m. It is an arranged laminate. When the core piece 31m and the gap material 31g are integrated with an adhesive, it is easy to handle and it is expected that noise can be reduced by firmly fixing the core piece 31m and the gap material 31g. In addition, when the core piece 31m and the gap material 31g are integrated with an adhesive tape or the like, it is easy to handle. The outer core portion 32 is a core piece made of a soft magnetic material.

Here, the inner core portion 31 has a rectangular parallelepiped shape, and the outer core portion 32 has a columnar shape in which the upper surface and the lower surface in FIG. 3 have a dome shape (a deformed trapezoidal shape in which the cross-sectional area decreases outward from the inner end surface 32e). The shape of the inner core portion 31 (core piece 31m / gap material 31g) and the shape of the outer core portion 32 can be appropriately selected. In addition, here, the surface (the lower surface in FIG. 3) facing the metal member (here, the bottom plate portion 40 (FIG. 2)) in the outer core portion 32 is the surface facing the metal member in the coil 2 (the lower surface in FIG. 3). The size of the outer core portion 32 is adjusted to be flush with each other. That is, when the magnetic core 3 is assembled in an annular shape, the outer peripheral surface (particularly the lower surface) of the outer core portion 32 protrudes from the outer peripheral surface of the inner core portion 31. By doing so, the opposing surface of the combined body 10 to the metal member is mainly composed of the lower surfaces of the two outer core portions 32 and the lower surface of the coil 2, and not only the coil 2 but also the outer core portion 32 includes the bonding layer 42. To touch.

The core piece constituting the inner core portion 31 and the outer core portion 32 has a molded body using an insulating group and a soft magnetic powder typified by an iron group metal such as iron or an alloy thereof, an oxide containing iron, or the like. A laminated plate body in which a plurality of magnetic thin plates (for example, an electromagnetic steel plate typified by a silicon steel plate) is laminated may be mentioned. The molded body is a compact material (typically using a coating powder having an insulation coating), a sintered body, a composite material obtained by injection molding or cast molding of a mixture containing soft magnetic powder and resin. Etc. Here, each core piece is a powder compact of soft magnetic metal powder containing iron such as iron or steel.

A known material can be used for the gap material 31g. The specific material of the gap material 31g is a mixture containing a nonmagnetic material such as alumina or unsaturated polyester, a nonmagnetic material such as polyphenylene sulfide (PPS) resin, and magnetic powder (for example, soft magnetic powder such as iron powder). Etc.

In addition, although each core piece which comprises the magnetic core 3 shall be the thing of the same specification (compact compact | molding | casting body) comprised from the uniform material here, it is magnetic with the inner core part 31 and the outer core part 32. Characteristics and specifications can be varied. For example, it is possible to adopt a form in which a green compact and a composite material are combined, or a form in which composite materials having different materials and mixed amounts of soft magnetic powder are combined.

Furthermore, the reactor 1 also includes an insulator 5 interposed between the coil 2 and the magnetic core 3, and is excellent in insulation between the coil 2 and the magnetic core 3. As shown in FIG. 3, the insulator 5 shown in this example includes a pair of peripheral wall portions 51 interposed between the coil element 2a or the coil element 2b and the inner core portion 31 to insulate them, and the coil elements 2a and 2b. And a pair of frame plate portions 52 that are interposed between the inner end surface 32e and the inner end surface 32e of the outer core portion 32 to insulate them. The shape of the insulator 5 shown in FIG. 3 is an example, and can be changed as appropriate.

Here, the peripheral wall 51 is composed of divided members 512 and 514 having a bowl-shaped cross section. The shape of the dividing members 512 and 514 can be selected as appropriate. Here, the dividing members 512 and 514 are formed so as to partially cover the outer periphery of the inner core portion 31. Therefore, in the form having the sealing resin described later, it is easy to deaerate at the time of filling the sealing resin, it is excellent in manufacturability, and the contact area between the inner core portion 31 and the sealing resin can be increased, thereby suppressing noise. It is expected to be possible. By configuring the peripheral wall portion 51 with the plurality of divided members 512 and 514, the peripheral wall portion 51 is easily arranged on the outer periphery of the inner core portion 31, and the assembly workability is excellent.

The frame plate portion 52 is a B-shaped flat plate member having a pair of openings (through holes) into which the two inner core portions 31 can be inserted. Here, when the frame plate portion 52 is assembled to the coil 2, the partition portion 52b disposed so as to be interposed between the coil elements 2a and 2b, the connecting portion 2r of the coil 2, and the one outer core portion 32. And a flat plate-like pedestal 52p. The partition part 52b protrudes from one surface of the frame plate part 52 toward the coil side, and the pedestal 52p protrudes from the other surface of the frame plate part 52 toward the outer core part 32 side. You may abbreviate | omit the partition part 52b and the base 52p.

As a constituent material of the insulator 5, an insulating material such as PPS resin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, liquid crystal polymer, or the like can be used.

In addition, a core component in which one or both of the inner core portion 31, the peripheral wall portion 51, and the one frame plate portion 52 of the magnetic core 3 are integrally formed with a resin can be obtained. As this resin, thermoplastic resins such as PPS resin, PTFE resin, LCP, nylon 6, nylon 66, and PBT resin can be used.

(Case)
The case 4 is a box that includes a flat bottom plate portion 40 on which the combined body 10 is placed and a frame-shaped side wall portion 41 that surrounds the periphery of the combined body 10. Yes (Figure 1).

The bottom plate portion 40 is typically a plate material fixed in contact with the installation target when the reactor 1 is installed on the installation target. Since the bottom plate portion 40 is used for the heat dissipation path of the coil 2, it is generally made of a metal that is a material having a high thermal conductivity. Specific examples of the metal include aluminum and its alloys, magnesium and its alloys, copper and its alloys, silver and its alloys, iron and austenitic stainless steel. Aluminum, magnesium, and their alloys can be made into lightweight cases. The thickness of the bottom plate portion 40 is, for example, about 2 mm or more and 5 mm or less in consideration of strength, shielding properties, heat dissipation, noise characteristics, and the like. Here, the bottom plate portion 40 is made of an aluminum alloy, and the thermal conductivity of the bottom plate portion 40 is sufficiently higher than the thermal conductivity of the side wall portion 41 described later.

The outer shape of the bottom plate portion 40 can be selected as appropriate. Here, the bottom plate portion 40 has a rectangular shape as shown in FIG. 2 and has mounting portions 400 protruding from the four corners. The side wall portion 41 also has an attachment portion 411. When the case 4 is formed by assembling the bottom plate portion 40 and the side wall portion 41, the attachment portion 400 of the bottom plate portion 40 and the attachment portion 411 of the side wall portion 41 overlap. Bolt holes 400h and 411h are provided in the attachment portions 400 and 411, respectively. Bolts (not shown) for fixing the case 4 to the installation target are inserted through the bolt holes 400h and 411h. The shape, the number, and the like of the attachment portions 400 and 411 can be selected as appropriate. If the bolt hole 411h of the side wall part 41 is comprised with a metal pipe, even if the side wall part 41 is comprised with resin so that it may mention later, it is excellent in intensity | strength.

In addition, although the installation state in which the baseplate part 40 becomes downward is shown here, the installation state in which the baseplate part 40 becomes an upper side or a side is also possible.

The side wall portion 41 is a frame-like body (here, a rectangular shape), and the whole is made of an insulating resin. Therefore, even when the coil 2 and the side wall 41 are arranged close to each other as shown in FIG. 1 (for example, the interval between the outer peripheral surface of the coil 2 and the inner surface of the side wall 41 is about 0 mm or more and 1.0 mm or less), Excellent insulation. Moreover, the reactor 1 can be reduced in size by reducing the said space | interval. Examples of the insulating resin include PBT resin, urethane resin, PPS resin, acrylonitrile-butadiene-styrene (ABS) resin, and the like.

When at least a part of the side wall 41 is made of metal (particularly nonmagnetic metal such as aluminum or magnesium), an improvement in heat dissipation and a shielding function can be expected. When all the side wall portions 41 are made of insulating resin as in this example, (1) excellent insulation between the coil 2 and the case 4 is achieved. (2) Even a complicated shape is easily manufactured by injection molding or the like. (3) It has the advantage that weight reduction can be achieved.

Further, here, the side wall portion 41 includes two flange portions 410 made of a flat plate covering a part of the opening of the case 4 (FIG. 2). By providing the flange 410, (1) improvement of vibration resistance, (2) improvement of rigidity of the case 4 (particularly the side wall part 41), and (3) external environment of the magnetic core 3 (particularly the outer core part 32). Various effects such as protection from mechanical and mechanical protection, and (4) prevention of falling off of the combined body 10 can be obtained. Here, one flange portion 410 (left side in FIG. 2) is used as a terminal block to which the terminal fitting 8 is fixed. Further, a terminal groove is provided in the flange 410 so that the terminal fitting 8 can be positioned. Further, here, after the terminal fitting 8 is disposed on the flange 410, the upper portion thereof is covered with a flat terminal fixing member 9, and the terminal fixing member 9 is fixed to the flange 410 with a bolt 91 to form a terminal block. is doing. The terminal fixing member 9 is preferably formed of the above-described insulating resin. It is also possible to insert-mold the terminal fitting 8 into the side wall portion 41 to form a side wall portion including the terminal fitting 8.

Here, the bottom plate portion 40 and the side wall portion 41 are integrated by the connecting bolt as described above, but an adhesive may be used together with the connecting bolt. Or you may connect the baseplate part 40 and the side wall part 41 only using an adhesive agent. When using an adhesive, for example, the double-sided adhesive sheet 420 has the same size as the bottom plate part 40, and the large double-sided adhesive sheet 420 allows the bonding layer 42 and the adhesive layer to join the bottom plate part 40 and the side wall part 41 to each other. Both of them can be formed. That is, the bonding layer 42 can be constituted by a part of the double-sided adhesive sheet 420 and the adhesive layer for integrating the case 4 can be constituted by the other part. In this embodiment, the curing step of the bonding layer 42 and the curing step of the adhesive layer that bonds the bottom plate portion 40 and the side wall portion 41 can be performed simultaneously, and the curing step can be reduced. Therefore, this form can improve productivity.

(Other components: sealing resin)
The case 4 may be filled with a sealing resin (not shown). The sealing resin fixes the position of the assembly 10 stored in the case 4, mechanical protection of the assembly 10 and the like, and protection from the external environment (improves corrosion resistance). Can be improved. In this embodiment, for example, when the end of the winding 2w is exposed from the sealing resin, the end of the winding 2w and the terminal fitting 8 are easily joined. After joining the end part of the winding 2w and the terminal fitting 8, it is also possible to have a form in which the joining portion is embedded in the sealing resin.

Examples of the sealing resin include insulating resins such as an epoxy resin, a urethane resin, and a silicone resin. When the sealing resin is a resin containing a filler made of ceramic described in the section of the material of the insulating sheet 422 described above, heat dissipation and insulation can be improved.

In the form including the sealing resin, if a packing (not shown) is provided between the bottom plate portion 40 and the side wall portion 41, the uncured resin leaks from the gap between the bottom plate portion 40 and the side wall portion 41. Can be prevented. When the bottom plate portion 40 and the side wall portion 41 are integrated with an adhesive, the adhesive can be sealed between the two to prevent leakage of uncured resin, so that packing can be omitted.

(Other components: lid)
The reactor 1 can be configured to include a lid (not shown) that covers the opening of the case 4. Examples of the constituent material of the lid include the insulating resin described in the section of the material of the side wall 41. In the form having a lid, it is possible to reduce noise, mechanically protect the assembly 10 and protect it from the external environment (improvement of corrosion resistance), avoid contact with external parts, and ensure insulation.

(Use)
The reactor 1 described above is used in applications where the energization conditions are, for example, maximum current (DC): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, and operating frequency: about 5 kHz to 100 kHz, typically an electric vehicle or a hybrid It can be suitably used for a component part of an in-vehicle power converter such as an automobile.

[Embodiment 2]
In Embodiment 1 mentioned above, the form in which the baseplate part 40 and the side wall part 41 are independent members was demonstrated. In addition, it can be set as the form which provides the case which consists of a box body in which the baseplate part and the side wall part were shape | molded integrally. In this form, when the whole case is comprised with metals, such as the above-mentioned aluminum, the whole case can be utilized for a thermal radiation path | route and heat dissipation is improved. In this case, the above-mentioned double-sided adhesive tape 420 is also disposed between the coil and the side wall of the case and cured at the same time, so that an insulating sheet is interposed between the coil and the side wall of the case. . In this case, even if the coil is disposed close to the side wall, that is, even if the distance between the coil and the side wall of the case is shortened (for example, 0.5 mm or less), the insulation between the coil and the case is improved. It is done.

[Embodiment 3]
In the first and second embodiments described above, the embodiment including the case has been described. In addition, it can be set as the form which does not have a case. In this case, it replaces with the baseplate part 40, and it is set as the form which provides the metal member interposed between the coil 2 and the installation object of the reactor 1. FIG. If the metal member is flat or has a flat surface like the above-described bottom plate portion 40, the double-sided adhesive tape 420 and the combination 10 of the coil 2 and the magnetic core 3 can be stably disposed and assembled. Excellent workability. Examples of the constituent material of the metal member include metals excellent in heat dissipation such as aluminum and its alloys described in the section of the bottom plate portion 40. Moreover, if this metal member is provided with the attachment part to installation object similarly to the baseplate part 40, the installation operation | work of a reactor can be performed easily. Further, in this embodiment, when the outer resin portion covering the outer periphery of the combined body 10 is provided, or the outer resin portion covering both the combined body 10 and the metal member is provided, mechanical protection of the combined body 10 is achieved. And protection from the external environment. In the latter form, the outer resin portion can also contribute to the integration of the combined body 10 and the metal member. When the outer resin portion is made of the above-described insulating resin, the insulation between the coil 2 and the like and the outside can be enhanced.

[Embodiment 4]
The reactors of the first to third embodiments can be used, for example, as a component part of a converter mounted on a vehicle or the like, or a component part of a power conversion device including the converter.

For example, a vehicle 1200 such as a hybrid vehicle or an electric vehicle is used for traveling by being driven by a main battery 1210, a power converter 1100 connected to the main battery 1210, and power supplied from the main battery 1210 as shown in FIG. Motor (load) 1220. The motor 1220 is typically a three-phase AC motor, which drives the wheel 1250 when traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, vehicle 1200 includes an engine in addition to motor 1220. In addition, in FIG. 5, although an inlet is shown as a charge location of the vehicle 1200, it can be set as the form which provides a plug.

The power conversion device 1100 includes a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 and performing mutual conversion between direct current and alternating current. The converter 1110 shown in this example boosts the DC voltage (input voltage) of the main battery 1210 of about 200V to 300V to about 400V to 700V when the vehicle 1200 is running, and supplies the inverter 1120 with power. In addition, converter 1110 steps down DC voltage (input voltage) output from motor 1220 via inverter 1120 to DC voltage suitable for main battery 1210 during regeneration, and causes main battery 1210 to be charged. The inverter 1120 converts the direct current boosted by the converter 1110 into a predetermined alternating current when the vehicle 1200 is running, and supplies the motor 1220 with electric power. During regeneration, the alternating current output from the motor 1220 is converted into direct current and output to the converter 1110. is doing.

As shown in FIG. 6, the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor L, and converts input voltage by ON / OFF repetition (switching operation). (In this case, step-up / down pressure) is performed. For the switching element 1111, a power device such as a field effect transistor (FET) or an insulated gate bipolar transistor (IGBT) is used. The reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that prevents the change of the current to flow through the circuit. As the reactor L, the reactors of the first to third embodiments are provided. In addition to excellent heat dissipation and insulation, the power conversion device 1100 and the converter 1110 are also excellent in heat dissipation, insulation, and productivity by including the reactor 1 that is excellent in productivity.

Vehicle 1200 is connected to converter 1110, power supply converter 1150 connected to main battery 1210, sub-battery 1230 serving as a power source for auxiliary machinery 1240, and main battery 1210. Auxiliary power supply converter 1160 for converting high voltage to low voltage is provided. The converter 1110 typically performs DC-DC conversion, while the power supply device converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Some power supply device converters 1150 perform DC-DC conversion. The reactors of the power supply device converter 1150 and the auxiliary power supply converter 1160 have the same configuration as that of the reactors of the first to third embodiments, and a reactor whose size and shape are appropriately changed can be used. In addition, the reactors of the first to third embodiments can be used for a converter that performs conversion of input power, and that only performs step-up or only performs step-down.

It should be noted that the present invention is not limited to the above-described embodiment, and can be appropriately changed without departing from the gist of the present invention.

The reactor of the present invention includes various converters such as an in-vehicle converter (typically a DC-DC converter) and an air conditioner converter mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, and a fuel cell vehicle. It can be suitably used as a component part of a power converter. The manufacturing method of the reactor of this invention can be utilized suitably for manufacture of the reactor utilized for the component of a converter and a power converter device.

DESCRIPTION OF SYMBOLS 1 Reactor 10 Combination 2 Coil 2a, 2b Coil element 2r Connection part 2w Winding 3 Magnetic core 31 Inner core part 31e End surface 31m Core piece 31g Gap material 32 Outer core part 32e Inner end surface 4 Case 40 Bottom board part 40i Inner surface 41 Side wall part 42 Bonding layer 400, 411 Mounting portion 400h, 411h Bolt hole 410 Hook portion 420 Double-sided adhesive sheet 422 Insulating sheet 425 Coil side adhesive layer 427 Metal side adhesive layer 5 Insulator 51 Peripheral wall portion 512, 514 Dividing member 52 Frame plate portion 52b Partition plate 52p base 8 terminal fitting 9 terminal fixing member 91 bolt 1100 power converter 1110 converter 1111 switching element 1112 drive circuit L reactor 1120 inverter 1150 power supply converter 1160 auxiliary power supply Converter 1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub battery 1240 Auxiliaries 1250 Wheel

Claims (7)

1. A reactor comprising a coil formed by spirally winding a winding and a magnetic core on which the coil is disposed,
   A metal member on which the coil is placed;
   Comprising a bonding layer interposed between the coil and the metal member to fix the coil to the metal member;
   The bonding layer includes both an insulating sheet made of an insulating material, a coil-side adhesive layer that contacts the coil, and a metal-side adhesive layer that contacts the metal member. Composed of adhesive sheet,
   A reactor in which the coil side adhesive layer is thicker than the metal side adhesive layer.
2. The reactor according to claim 1, wherein a thickness of the coil side adhesive layer is more than 30 µm and not more than 350 µm.
3. The reactor according to claim 1 or 2, wherein an adhesive constituting the coil-side adhesive layer is interposed between adjacent turns in the coil.
4. The winding comprises a conductor composed of a flat wire,
   The reactor according to any one of claims 1 to 3, wherein the coil is an edgewise coil.
5. A converter comprising the reactor according to any one of claims 1 to 4.
6. A power conversion device comprising the converter according to claim 5.
7. A reactor manufacturing method for manufacturing a reactor by assembling a coil formed by spirally winding a winding and a magnetic core on which the coil is disposed,
   Preparing a double-sided adhesive sheet comprising an insulating sheet composed of an insulating material and an adhesive layer formed on each of the front and back surfaces of the insulating sheet;
   Placing the double-sided adhesive sheet on a metal member on which a combination of the coil and the magnetic core is placed;
   Placing the combination on the double-sided adhesive sheet;
   Curing the adhesive layer provided on the double-sided adhesive sheet, and joining the coil and the metal member via the double-sided adhesive sheet;
   The double-sided adhesive sheet is a method for manufacturing a reactor in which the thickness of one adhesive layer in contact with the coil is thicker than the thickness of the other adhesive layer in contact with the metal member.

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