WO2016060001A1 - Reactor - Google Patents

Abstract

Provided is a reactor that makes it possible to reduce a gap formed around a sensor and to suitably maintain the contact state between a coil and the sensor. The reactor is provided with: a coil comprising a wound section obtained by winding a winding; a magnetic core comprising a part that is arranged on the inside and on the outside of the wound section; a sensor for measuring a physical quantity relating to the reactor; and a foamed resin that is in contact with both the coil and the sensor.

Description

Reactor

The present invention relates to a reactor used for a component of a power conversion device such as a vehicle-mounted DC-DC converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor that can reduce a gap generated around a sensor and can maintain a good contact state between a coil and the sensor.

Reactor is one of the circuit components that perform voltage step-up and step-down operations. Patent Document 1 discloses a combination of a coil having a pair of winding portions formed by spirally winding a winding and an annular magnetic core as a reactor used in a converter mounted on a vehicle such as a hybrid vehicle. Is stored in a case and further embedded in a sealing resin filled in the case.

If the coil generates heat when energized, it may lead to an increase in reactor loss. Therefore, Patent Document 1 discloses a reactor including a temperature sensor that measures the temperature of a coil so that energization control and the like can be performed according to the temperature of the coil. More specifically, in Patent Document 1, the end surface shape of the coil winding portion is a rectangular shape having a corner R portion, and a trapezoidal space sandwiched between corner R portions disposed opposite to each other in the pair of winding portions. The temperature sensor is disposed on the plate, the temperature sensor is held by a flat sensor holder, the sensor holder is inserted between the pair of winding portions to hold the temperature sensor in a predetermined position, and the coil and the magnetic core It is disclosed that the sensor holder is engaged with an insulator interposed between the two and positioned.

JP 2014-093375 A

A reactor capable of more appropriately measuring the physical quantity of the reactor such as the temperature of the coil is desired.

In the reactor of Patent Document 1, the temperature sensor is supported at a predetermined position near the coil by the sensor holder, and the temperature of the coil can be measured. However, in this reactor, a space exists around the temperature sensor except for the contact portion with the coil (see FIG. 5 of Patent Document 1). For example, when air is present in this space, air is a substance having poor thermal conductivity, and therefore the presence of air can cause a decrease in temperature measurement accuracy. Moreover, in this reactor, since the contact state of a coil and a temperature sensor is maintained by the mechanical support by a sensor holder, when a vibration is added to a reactor, a clearance gap may arise between a coil and a temperature sensor. That is, air can be interposed between the coil and the temperature sensor. In this case, the temperature measurement accuracy may be further reduced. Therefore, the physical quantity of the reactor, such as the temperature of the coil, can be measured with high accuracy, and even when vibration is applied, the contact state between the coil and the sensor can be maintained well, and the reactor is excellent in physical quantity conductivity from the coil to the sensor. Development is desired.

On the other hand, when the sealing resin is provided, the sealing resin is filled in the space formed around the temperature sensor. If the sealing resin is excellent in thermal conductivity, the sealing resin can be used as a heat transfer path from the coil to the temperature sensor, and the measurement accuracy can be improved. Further, the contact state between the coil and the temperature sensor can be fixed by the sealing resin, and the contact state can be easily maintained even when vibration is applied. However, in this case, a case and a sealing resin are necessary, which causes an increase in the number of parts, an increase in the number of processes, and an increase in manufacturing time. Therefore, even if it does not have sealing resin, the structure which can maintain the contact state of a coil and a temperature sensor favorably, and is excellent in the conductivity of the physical quantity from a coil to a sensor is desired.

Therefore, one of the objects of the present invention is to provide a reactor that can reduce the gap generated around the sensor and maintain a good contact state between the coil and the sensor.

A reactor according to an aspect of the present invention includes a coil having a winding portion formed by winding a winding, a magnetic core having a portion disposed inside and outside the winding portion, a sensor for measuring a physical quantity of the reactor, A foamed resin in contact with both the coil and the sensor.

The above-mentioned reactor can reduce the gap generated around the sensor and can maintain a good contact state between the coil and the sensor.

It is a schematic perspective view which shows the reactor of Embodiment 1. FIG. FIG. 2 is a cross-sectional view showing a state in which the reactor according to the first embodiment is cut along the (II)-(II) cutting line shown in FIG. FIG. 3 is an exploded perspective view illustrating a manufacturing process of the reactor according to the first embodiment. It is a top view which shows the reactor of Embodiment 2. FIG. It is sectional drawing which shows the state which cut | disconnected the reactor of Embodiment 3 by the plane orthogonal to the axial direction of a coil.

[Description of Embodiment of the Present Invention]
First, embodiments of the present invention will be listed and described.
(1) The reactor which concerns on 1 aspect of this invention measures the physical quantity of the coil which has the coil | winding part formed by winding a coil | winding, the magnetic core which has the part arrange | positioned inside and outside the said winding part, and a reactor. A sensor, and a foamed resin that contacts both the coil and the sensor.

The contact between the sensor and the foamed resin is not only when the sensor and the foamed resin are in direct contact, but also through a solid substance such as a protective material that covers and protects the sensor (for example, a protective part described later) And indirect contact. It is preferable that the substance has a physical quantity transferability equivalent to that of air, and more excellent in the physical quantity transferability (for example, thermal conductivity) than air.

In the above-described reactor, a gap that can be generated in the area surrounding the sensor and in the vicinity of the contact point with the coil is easily filled by the volume expansion of the foamed resin in the manufacturing process, and the gap that can be generated around the sensor can be reduced. . Depending on the amount of foamed resin, this gap can be substantially eliminated.

The above-described reactor can maintain a good contact state between the coil and the sensor because the volume-expanded foamed resin can sufficiently contact both the coil and the sensor, and preferably can be in close contact. When the foamed resin has a certain level of adhesive force, the reactor makes it easier for the reactor to maintain the contact state between the coil and the sensor. That is, it can be said that the adhesive force of the foamed resin contributes to fixing the coil and the sensor. Such a reactor can sufficiently reduce the contact area of the sensor with an external atmosphere, for example, air, even when no sealing resin is provided.

Furthermore, since the above-mentioned reactor is in contact with both the coil and the sensor, the above-described reactor is a substance (resin component of the foamed resin) that has better physical quantity transferability (eg, thermal conductivity) than the air between the coil and the sensor. ). Therefore, said reactor can utilize the resin component of foamed resin for the transmission path which transmits the said physical quantity from a coil to a sensor.

The above reactor including such a foamed resin can transfer the physical quantity from the coil to the sensor satisfactorily and increase the measurement accuracy. In addition, the reactor described above may be used in an environment where vibrations can be applied, such as a case where no sealing resin and a case are provided, or a case where vibration is applied, such as an in-vehicle component, and even in both cases, the coil temperature, etc. The physical quantity of the reactor can be measured well.

In addition, since the foamed resin in the manufacturing process, that is, the unfoamed resin is thin, the above-described reactor can be easily disposed in a narrow portion such as a gap between the coil and the sensor, and is excellent in manufacturability.

(2) As an example of the above-described reactor, the coil includes a pair of winding parts whose end face shape is a rectangular shape having a corner R part, and the pair of winding parts have parallel axes of the winding parts. The sensor is supported by the corner R portion, and a part of the foamed resin is provided between the pair of winding portions.

In the said form, when a part of sensor contacts at least one corner | angular R part among the both winding parts of a coil, or by contacting the said corner | angular R part via a part of foamed resin, a sensor is Supported by the corner R. In other words, in the above embodiment, the sensor is placed near the corner R. In the said form, since a part of foaming resin exists in the area | region pinched | interposed by a pair of winding part, ie, a very narrow area | region, it is easy to contact with both a coil and a sensor. From these things, the said form is excellent in the transmission property of the physical quantity from a coil to a sensor. In particular, in a configuration in which the physical quantity of the reactor is the coil temperature and a temperature sensor is included as a sensor and this temperature sensor is supported by the corner R portion, the coil temperature is relatively high in the region sandwiched between the pair of winding portions. The coil temperature can be satisfactorily measured in the vicinity of the easy-to-use corner R. Further, since the unfoamed resin is thin, it can be easily arranged even in a relatively narrow gap such as between the winding portions, and the above form is excellent in manufacturability.

(3) As a more specific example of the reactor of the above (2), there is a mode in which a part of the foamed resin is provided in a region between the pair of winding parts and inside the corner R part.

In addition to the above effect (2), the above aspect has the following effects. A part of the foamed resin exists in an inner region that is narrower than between the corner R portions in the region sandwiched between the pair of winding portions. It can be said that the foamed resin present in the inner region reduces the gap that may occur around the sensor supported by the corner R portion. Furthermore, the physical quantity transmission path can be satisfactorily constructed by the resin component of the foamed resin existing around the sensor. Therefore, the said form can measure the physical quantity of a reactor accurately. Further, since the unfoamed resin is thin as described above, it can be easily disposed in the narrow inner region described above, and the above form is excellent in manufacturability.

In particular, in the form in which the physical quantity of the reactor is the coil temperature, the temperature sensor is included as a sensor, and the temperature sensor is supported by the corner R portion, the inner region is filled with the foamed resin as described above, and the gap is sufficiently provided. Since it is reduced, the heat transfer path by the resin component of the foamed resin existing around the temperature sensor can be constructed well, and the temperature of the coil can be accurately measured. As a result, this embodiment is expected to be able to satisfactorily control energization of the coil based on the measured temperature and to easily reduce the heat loss of the reactor.

(4) As a more specific example of the reactor of (2) or (3) above, a resin in which a protective part covering the sensor and a partition part arranged between the pair of winding parts are provided integrally A molded part, and a part of the foamed resin is provided in a space surrounded by the wound part and the outer peripheral surface of the resin molded part.

In addition to the above-described effects (2) or (3), the above-described form has the following effects. Since the sensor is mechanically protected by the protection unit, it is possible to prevent measurement failure due to pressure loss or damage of the sensor, for example, increase in measurement error or occurrence of an unmeasurable situation. In addition, since a part of the foamed resin is filled in a space surrounded by the winding part and the resin molded part that are arranged to face each other, a gap that may be generated around the sensor can be reduced by the foamed resin and the resin molded part. . For example, if a part of the foamed resin is filled between the outer peripheral surface of one winding part and one surface of the partition part, the sensor is predetermined by the three parties of the foamed resin, the partition part, and the corner R part. Can be favorably supported at the position (near corner R). Therefore, this form is easy to maintain the contact state between the coil and the sensor by the above-mentioned three parties. For example, if both the outer peripheral surface of one winding part and one surface of the partition part and the outer peripheral surface of the other winding part and the other surface of the partition part are filled with foamed resin, respectively It is easier to further support the sensor at a predetermined position. For this reason, this embodiment can effectively reduce the gap that may be generated around the sensor by the above-mentioned three parties, and further easily maintain the contact state between the coil and the sensor. From these points, the said form can measure the physical quantity of a reactor appropriately over a long period of time. Moreover, the said form is excellent also in manufacturability from the following points.
1. By providing the resin molding part, it is easy to handle the sensor, and it is easy to place the sensor at a predetermined position.
2. As compared with the case where the sensor and the sensor holder described in Patent Document 1 are separate and separate members and need to be assembled, the assembly is unnecessary and the number of manufacturing steps is small.
3. In the manufacturing process, the partition portion can be used as a support member for the unfoamed resin, and the sensor and the unfoamed resin can be simultaneously disposed at predetermined positions.
When unfoamed resin is supported by the partition portion, a sheet having a large area or the like can be easily used as the unfoamed resin. By using a large sheet, it is possible to secure a sufficient amount of foaming and to satisfactorily fill the space around the sensor with foamed resin.

(5) As an example of the reactor described above, the reactor includes a facing member disposed to face the end surface of the winding portion, and the sensor is disposed in a space sandwiched between the end surface of the winding portion and the facing member. A form in which a part of the foamed resin is interposed between the end face of the wound portion and the sensor can be mentioned. Examples of the facing member include a core piece provided in the magnetic core, a resin mold portion that covers the core piece, and an interposed member interposed between the core piece and the coil.

The above space is a relatively narrow space, and when the sensor is arranged in such a space, the sensor easily comes into contact with the end face of the coil winding portion, and the contact area of the sensor with the coil (indirect through the foamed resin) (Including contact) is easy to increase. Of the foamed resin, a portion interposed between the end face of the winding portion and the sensor can be in close contact with both the coil and the sensor. Such a configuration can reduce a gap that may occur around the sensor, and can easily maintain a contact state between the coil and the sensor, and can satisfactorily transmit a physical quantity using a resin component. Furthermore, when the winding part is formed by spirally winding the winding, and the space is an inclined space according to the end face shape of the winding part, particularly along one of the winding directions of the winding. In the case of a tapered space, if the sensor is inserted and arranged in the inclined space during the manufacturing process, the sensor can be easily positioned and is not easily displaced. From these things, the said form can measure the physical quantity of a reactor accurately. Further, the space is a dead space of the coil, and it is difficult to increase the size of the reactor due to the presence of the sensor, and the form is small. In addition, when the sensor is difficult to be displaced, the sensor holder can be omitted, the number of parts is small, and the manufacturability is excellent.

(6) As an example of the above reactor, the coil includes a heat radiating plate on which an assembly including the coil and the magnetic core is placed, and the coil has the winding part whose end face shape is a rectangular shape having a corner R part. A pair of winding portions are arranged in parallel so that the axes of the respective winding portions are parallel to each other, and the sensor includes the corner R portion disposed opposite to the pair of winding portions and the heat radiating plate. A form in which the foamed resin is disposed in the formed trapezoidal space and at least a part of the foamed resin is provided in the trapezoidal space is exemplified.

In the above embodiment, a part of the sensor arranged in the trapezoidal space easily comes into contact with at least a part of both winding parts of the coil, for example, the corner R part, and the contact area of the sensor with the coil is easily increased. In addition, at least a part of the foamed resin, and substantially all, is filled in a closed space surrounded by the corner R portion, the heat radiating plate, and the sensor that are disposed to face each other. Therefore, the foamed resin is more likely to be in close contact with both the coil and the sensor, and the gap that may occur around the sensor is more likely to be reduced. From these things, the said form can measure the physical quantity of a reactor more accurately irrespective of the presence or absence of sealing resin. Further, since the trapezoidal space can be said to be a dead space of the coil, the above-described form can be made compact. In addition, the said form is excellent in heat dissipation by providing a heat sink.

(7) As an example of the reactor, the magnetic core may include a core piece that includes a soft magnetic material and a resin mold portion that covers the core piece.

Even if it does not have sealing resin and a case, the above-mentioned form has effects such as mechanical protection of the core piece, protection from the external environment, and rigidity improvement by integration of the core piece by having the resin mold part. . Further, even if no sealing resin is provided as described above, the gap that can be generated around the sensor by the foamed resin existing around the sensor (reduction of contact area with air in the sensor), the coil, and the sensor The physical quantity of the reactor can be measured satisfactorily by maintaining the contact state with the sensor and by constructing a physical quantity transmission path by the resin component of the foamed resin existing around the sensor. Therefore, the said form can be said to be a suitable structure when sealing resin and a case are abbreviate | omitted. In this case, it is small. In addition, the above-mentioned form has a resin mold part, thereby improving the insulation between the core piece and the coil, reducing the number of assembled parts, improving the handleability of the assembled parts, and omitting the sealing resin and the case. It has effects such as improvement of properties and weight reduction.

(8) As an example of the reactor described above, a form in which the sensor includes a thermistor can be given.

In the above embodiment, the temperature of the coil can be measured by providing a thermistor which is a heat sensitive element. Even if no sealing resin is provided as described above, the gap that can occur around the sensor due to the foamed resin present around the sensor (reduction of the contact area with air in the sensor), and the coil made of foamed resin By maintaining the contact state with the sensor and constructing the heat transfer path by the resin component of the foamed resin existing around the sensor, the above-described form can measure the coil temperature appropriately and accurately.

[Details of the embodiment of the present invention]
Embodiments of the present invention will be specifically described below with reference to the drawings. The same reference numerals in the figure indicate the same names.

[Embodiment 1]
The reactor 1A according to the first embodiment will be described with reference to FIGS. In FIG. 1, a part of one winding part 2 a of the coil 2 is notched so that the foamed resin 4 </ b> A can be easily understood. FIG. 1 shows an example of the installation state of the reactor 1A, and the lower surface of the reactor 1A is the installation surface. Hereinafter, in the installation state shown in FIG. 1, the installation side may be referred to as the lower side, and the opposite side thereof may be referred to as the upper side (this also applies to FIG. 5 described later).

(Reactor)
-Overall structure The reactor 1A of Embodiment 1 has the coil 2 which has a pair of winding part 2a, 2b formed by helically winding the coil | winding 2w, and the part arrange | positioned inside and outside winding part 2a, 2b. The magnetic core 3 and a sensor member 7A having a sensor 70 (FIG. 2) for measuring the physical quantity of the reactor 1A are provided. This reactor 1A is characterized in that it includes a foamed resin 4A that contacts both the coil 2 and the sensor member 7A.

Besides, the reactor 1A shown in this example is typically used by being attached to an installation target (not shown) such as a converter case in the state where the outer periphery is not covered with the sealing resin. For example, the reactor 1A is attached to an installation target having a cooling structure in which a liquid refrigerant is supplied and the reactor 1A is in contact with the liquid refrigerant. Therefore, the magnetic core 3 includes a soft magnetic material, and includes a plurality of core pieces 31m (FIG. 3), a core piece 32m,... That form a magnetic path, and a resin mold portion that covers these core pieces 31m, 32m,. It is set as the covering member provided with (middle resin mold part 310m, side resin mold part 320m). Hereinafter, each component will be described in order.

.. Coil The coil 2 includes a pair of cylindrical winding portions 2a and 2b formed by spirally winding one continuous winding 2w as shown in FIG. 3, and a part of the winding 2w And a connecting portion 2r for connecting both winding portions 2a and 2b. The pair of winding parts 2a and 2b are arranged in parallel (side by side) so that the axes of the winding parts 2a and 2b are parallel to each other. The winding 2w in this example is a covered rectangular wire (so-called enameled wire) including a flat wire conductor (copper or the like) and an insulating coating (polyamideimide or the like) covering the outer periphery of the conductor, and the winding portion 2a, 2b is an edgewise coil.

The winding parts 2a and 2b shown in this example are square cylinders with rounded corners, and the end surfaces of the winding parts 2a and 2b are rectangular shapes having four corner R parts 20, respectively. Therefore, the outer peripheral surface of each winding part 2a, 2b has a rectangular plane (upper and lower surfaces and left and right surfaces in FIG. 3) formed by arranging the side surfaces of the plurality of windings 2w, and corners R positioned at the four corners. And an arcuate curved surface that forms part 20. Moreover, as shown in the cross section cut by the plane orthogonal to the axial direction of the coil 2 as shown in FIG. 2, the curved surfaces of the corner R portions 20 and 20 arranged opposite to each other in the pair of winding portions 2a and 2b arranged in parallel. And, of the outer peripheral surfaces of the winding portions 2a and 2b, trapezoidal spaces 27A and 27C are formed at two locations above and below by the virtual surface 200 that connects the above-described rectangular upper planes or lower planes in the parallel direction. (See also FIG. 5 for space 27A). The reactor 1 </ b> A in this example is characterized in that a downward trapezoidal space 27 </ b> A provided on the upper side is a place where the sensor 70 is disposed. The upper trapezoidal space 27 </ b> A including the space sandwiched between the corner R portions 20, 20 arranged opposite to each other is an area where the coil 2 can be at the highest temperature, and is one of the areas suitable for the temperature measurement location of the coil 2. I can say that. Further, the upper trapezoidal space 27 </ b> A is a space opened upward when the reactor 1 </ b> A in the manufacturing process is arranged in the installed state. Therefore, the sensor member 7A can be easily inserted and arranged from above the winding portions 2a and 2b. Further, two trapezoidal spaces 27 </ b> A and 27 </ b> C in the upper and lower portions are dead spaces of the coil 2. The reactor 1A of the first embodiment can effectively use the dead space by setting the trapezoidal space 27A as the arrangement location of the sensor member 7A, and prevents the reactor 1A from becoming bulky due to the presence of the sensor member 7A. Can be small. The size of the trapezoidal spaces 27A and 27C varies depending on the size (rounding radius) of the corner R portion 20. As the rounding radius is increased, the trapezoidal spaces 27A and 27C are increased. If the radius is too large, the coil 2 is enlarged and the reactor 1A is enlarged. Therefore, the sensor member 7A may be selected corresponding to the size of the trapezoidal spaces 27A and 27C. In FIG. 2, a wiring 78 (FIG. 1), which will be described later, is omitted for easy understanding.

Both ends of the winding 2w are drawn out from the winding portions 2a and 2b in an appropriate direction, the insulating coating at the tip is peeled off, and a terminal fitting (not shown) is connected to the conductor. The coil 2 is electrically connected to an external device (not shown) such as a power source via a terminal fitting.

..Magnetic core The magnetic core 3 is disposed so that the coil 2 is disposed in the winding portions 2a and 2b of the coil 2, and the coil 2 is not substantially disposed and protrudes outside the winding portions 2a and 2b. A closed magnetic path when the coil 2 is excited. The portion inside the former coil 2 is mainly composed of a laminate including a plurality of core pieces 31m, and the portion outside the latter coil 2 is mainly composed of core pieces 32m.

The magnetic core 3 shown in this example includes a core component 310 including a plurality of columnar core pieces 31m,... And a middle resin mold portion 310m that covers the core pieces 31m,. A pair of columnar core pieces 32m and 32m shown, and a side resin mold part 320m (FIG. 1) covering each core piece 32m are used as components. The magnetic core 3 is assembled with a pair of core pieces 32m and 32m so as to connect a pair of core components 310 and 310 arranged side by side. In this state, the side resin mold portion 320m covers the core pieces 32m and 32m. The molded product is molded and fixed as an annular body.

... Core pieces The core pieces 31m and 32m contain 30% by volume or more and more than 50% by volume of a soft magnetic material to form a magnetic path. Specifically, a compacted body obtained by compression molding a soft magnetic metal powder such as iron or an iron alloy (Fe—Si alloy, Fe—Ni alloy, etc.) or a coating powder further provided with an insulating coating, soft magnetic powder and resin Composite materials containing can be used. In this example, the green compact is used. The number, shape, size, composition, and the like of the core pieces included in the magnetic core 3 can be changed as appropriate.

The core piece 31m shown in this example has a rectangular parallelepiped shape with rounded corners, and the core piece 32m is provided so that the inner end face 32e to which the pair of core components 310 and 310 are connected is orthogonal to the axial direction of the coil 2. The upper surface and the lower surface have a dome shape (deformed trapezoidal shape) whose cross-sectional area decreases outward from the inner end surface 32e. In this example, the coil 2 and the magnetic core 3 are assembled, and the installation surface of the coil 2, that is, the lower surfaces of the winding portions 2a and 2b, and the lower surface of the side resin mold portion 320m are substantially flush with each other. The lower surface of the core piece 32m protrudes from the lower surface of the core component 310 (the lower surface of the core piece 31m). As a result, the installation surface of the reactor 1A shown in this example is mainly composed of an installation surface (lower surface) of the side resin mold part 320m covering the two core pieces 32m and an installation surface of the coil 2 (of the winding parts 2a and 2b). Bottom surface). The outer shape of the reactor 1A has a simple shape with little unevenness.

... Resin mold part Middle resin mold part 310m provided in each core component 310 covers the entire outer periphery excluding a part along the outer shape with a plurality of core pieces 31m arranged at equal intervals. And a core coating portion provided on the surface. In this example, the end surface of the core piece 31m located at one end of the core part 310 is not covered with the resin mold part 310m but exposed (see the left core part 310 in FIG. 3). Moreover, the resin mold part 310m of this example has the gap part 310g which fills the gap between the adjacent core pieces 31m and 31m and functions as a gap.

The side resin mold part 320m has a core coating part covering the outer peripheral surface of the core piece 32m. Moreover, the resin mold part 320m of this example has a gap part (not shown) which fills the gap between the core piece 32m and the core piece 31m included in the core component 310 and functions as a gap.

That is, the resin mold portions 310m and 320m provided in the reactor 1A shown in this example are coated with the core pieces 31m and 32m, joined between the core pieces 31m and 31m to be a part in the coil 2, and the core component 310 (core piece 31m). It has various functions such as maintaining an annular body by joining the core piece 32m and forming a gap. In addition, instead of the gap due to the constituent resin of the resin mold portions 310m and 320m, a form having a gap material made of a nonmagnetic material such as alumina, for example, a material having a lower relative permeability than the core pieces 31m and 32m, an air gap It can be set as a form provided or a form without a gap.

In addition, the middle resin mold portion 310m shown in this example is integrally provided with a frame portion 315 interposed between the end surfaces of the winding portions 2a and 2b of the coil 2 and the inner end surface 32e of the core piece 32m, and the above-described core The covering portion and the frame portion 315 form an L-shaped molded body. The frame portion 315 includes a portion that covers one end surface of the core piece 31m held by the core covering portion, and a through hole 315h through which the core piece 31m (core covering portion) included in the other core component is inserted. One surface of the frame portion 315 is disposed opposite to the inner end surface 32e of the core piece 32m, and a part of the side resin mold portion 320m is joined thereto. The other surface of the frame portion 315 is a plane provided so as to be orthogonal to the axial direction of the winding portions 2a and 2b of the coil 2, and is disposed so as to face the winding portions 2a and 2b (see FIG. 1 and later-described drawings). 4).

As shown in FIG. 3, on the contact surface (one surface) of the frame portion 315 with the core piece 32m, there are two upper and lower protrusions 316, 316 for positioning the core piece 32m, the frame portion 315 and the core piece 32m. A plurality of rectangular protrusions 317 for forming gaps that facilitate introduction of the constituent resin of the side resin mold part 320m between the inner end surface 32e of the resin and the resin constituting the resin mold part 320m enter the core. A locking portion 318 having a function of increasing the bonding strength with the component 310 is provided. The locking portion 318 is a part of the ridge 316 and has an L-shaped cross section. Among the L-shaped portion, a piece parallel to the contact surface (one surface) in the frame portion 315, the contact surface (one surface), and A filling space for the above-described constituent resin is formed between them. On the other hand, the opposing surface (other surface) 315c of the frame portion 315 facing the coil 2 is provided with a partition plate 319 interposed between the winding portions 2a and 2b.

In addition, as shown in FIG. 1, the side resin mold part 320m shown in this example includes an attachment part 325 to which a bolt (not shown) for fixing the reactor 1A to the installation target is attached. The attachment portion 325 is a plurality of projecting pieces projecting outward from the coil in the core piece 32m (here, a total of four pieces), and includes a bolt hole 325h. The number of attachment portions 325, attachment positions, and the like can be changed as appropriate.

At least one of the above-described protrusion 316, protrusion 317, locking portion 318, partition plate 319, and attachment portion 325 can be omitted.

Resin mold parts 310m and 320m are composed of polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide such as nylon 6, nylon 66, nylon 10T, nylon 9T, nylon 6T, etc. Thermoplastic resins such as (PA) resin, polybutylene terephthalate (PBT) resin, acrylonitrile butadiene styrene (ABS) resin, and the like can be given. Other examples include thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins. When a resin containing a ceramic filler such as alumina or silica is used as the resin, the resin mold portions 310m and 320m having excellent thermal conductivity can be obtained, and the reactor 1A having excellent heat dissipation can be obtained.

-Sensor member Reactor 1A is provided with the sensor 70 which measures the physical quantity (FIG. 2). The sensor 70 is connected to a wiring 78 for transmitting the sensing information to an external device (FIGS. 1 and 3). If a connector portion (not shown) for connecting to an external device is provided at the end of the wiring 78, the connection workability with the external device is excellent.

Sensor 70 can be appropriately selected according to a desired physical quantity. When the physical quantity is temperature, the sensor 70 may be a thermosensitive element such as a thermistor, a thermocouple, or a pyroelectric element. When the physical quantity is current, voltage, magnetic field or the like, the sensor 70 may be one that can sense the magnetic field of the coil 2 such as a Hall element, a magnetoresistive element (MR element), a magnetic impedance element (MI element), or a search coil. It is done. In this example, a thermistor is provided as the sensor 70, and the reactor 1A can measure the temperature of the coil 2.

Reactor 1A preferably includes a protective member that mechanically protects sensor 70. Therefore, the reactor 1 </ b> A in this example includes a sensor member 7 </ b> A including a sensor 70 and a protection unit 727. Specifically, as shown in FIGS. 2 and 3, the sensor member 7 </ b> A is integrally provided with a protection portion 727 that covers the sensor 70 and a partition portion 722 disposed between the pair of winding portions 2 a and 2 b of the coil 2. The resin molding part 72 is provided. The protection part 727 is provided in a columnar shape as shown in FIG. 2, and the sensor 70 is embedded therein. The partition part 722 is a flat plate part extended from a part of the circumferential surface of the cylindrical protection part 727 in the diameter direction of the cylinder as shown in FIGS.

The protection unit 727 including the sensor 70 is disposed in the trapezoidal space 27A described above. This protective part 727 is arranged so as to contact at least one of the pair of corner R parts 20, 20 opposed to each other in the winding parts 2 a, 2 b, preferably both (enlarged view in a one-dot chain line circle in FIG. 2). reference). By this contact, the sensor 70 is supported by the corner R portions 20 and 20 via the protection portion 727. As the diameter phi ₇ of cylindrical protection portion 727 is larger than the distance W ₂ between planes opposing one of the winding portions 2a, 2b the outer peripheral surface of the, by the size of the protective portion 727 is adjusted, This arrangement is possible. In addition, the resin molding portion 72 shown in this example is configured such that the sensor member 7A is wound around the circumferential portions of the cylindrical protection portion 727 on the side opposite to the partition portion 722 in the diameter direction of the column. A pedestal portion 725 having a flat upper surface is provided so that it can be easily pressed in between. The width of the upper plane of the base portion 725 is larger than the diameter phi _7, readily pressed in the manufacturing process. When the pedestal part 725 is pressed during the manufacturing process, the diameter φ ₇ is larger than the interval W ₂ between the winding parts 2a and 2b, and thus the protective part 727 is disposed so as to face the corner R part 20 in the winding parts 2a and 2b. , 20 and is positioned in the trapezoidal space 27A.

The partition part 722 has a function of maintaining the state in which the sensor 70 is disposed in the trapezoidal space 27 </ b> A together with the foamed resin 4 </ b> A. The width W ₇₂ of the partition part 722 is smaller (thinner) than the interval W ₂ between the winding parts 2a and 2b, and the total width of the partition resin 722 and the foamed resin 4A interposed between the winding parts 2a and 2b is winding. The width W ₇₂ of the partition portion 722 is adjusted so as to be equal to or greater than the interval W ₂ between the turning portions 2a and 2b. As a result, the above arrangement state can be maintained satisfactorily. Moreover, the partition part 722 also functions as a guide when a part of the sensor member 7A is inserted between the winding parts 2a and 2b in the manufacturing process due to such a thinness. In addition, the partition part 722 has an insulating function between the winding parts 2a and 2b.

The area of the flat partition part 722 (the area of the part facing the plane of the winding parts 2a, 2b) can be selected as appropriate. Since the partition part 722 can be omitted as shown in Embodiments 2 and 3 to be described later, the area of the partition part 722 may be small. On the other hand, as shown in FIG. 3, if the area of the partition part 722 is increased to some extent, the space between the winding parts 2 a and 2 b is sufficiently filled with the partition part 722. As a result, a gap generated around the sensor 70 supported by the corner R portions 20 and 20 can be reduced. Furthermore, if the partition part 722 is large to some extent, the contact area between the winding parts 2a, 2b, the foamed resin 4A, and the partition part 722 increases, and the sensor member 7A (from the coil 2 through the foamed resin 4A) Heat conduction to the partition part 722⇒the protection part 727⇒the sensor 70) can be performed satisfactorily. That is, the partition part 722 also has a function as a heat transfer path between the coil 2 and the foamed resin 4A. Further, when an unfoamed resin sheet is used as a raw material for the foamed resin 4A in the manufacturing process, the partition portion 722 can easily support the resin sheet. In particular, when using a large resin sheet, it is easy to place the resin sheet in the vicinity of the sensor 70 (protection part 727), and the resin sheet is supported by the partition part 722, and between the winding parts 2a and 2b at the same time. There is an advantage in the manufacturing process that it can be inserted. The size (area) of the partition portion 722 may be selected according to the size of the raw material of the foamed resin 4A, the expansion coefficient, and the like. In addition, if the area of the partition part 722 is large, between winding part 2a, 2b can be divided more reliably, and insulation can be improved.

The partition portion 722 shown in this example has a simple shape such as a flat plate shape and is excellent in manufacturability. In addition, a hook (not shown) may be provided as in the sensor holder of Patent Document 1, and a protrusion or the like that can be engaged with the partition plate 319 of the frame portion 315 can be provided. In this case, the sensor member 7A can be easily and reliably positioned in the manufacturing process, and the sensor member 7A is prevented from being lifted from a predetermined position when the resin is foamed, and the sensor 70 is maintained at the predetermined position. Easy to do. When the hook does not have an engagement mechanism or the like, the sensor member 7A may be pressed so as not to float when the resin is foamed.

For example, PPS resin, PTFE resin, LCP, PA resin such as nylon 6 described above, thermoplastic resin such as PBT resin, ABS resin, unsaturated polyester resin, epoxy resin, urethane resin, etc. A thermosetting resin such as a silicone resin can be used. These resins generally have a higher thermal conductivity than air. Since the resin molding part 72 made of such a resin is interposed between the coil 2 and the sensor 70, at least a part of the resin molding part 72 is in direct contact with the coil 2 or the coil 2 via the foamed resin 4A. The heat from the coil 2 can be satisfactorily transmitted to the sensor 70 by being in contact with the sensor 70 indirectly. The resin molding part 72 can be easily formed by using an appropriate resin molding method such as injection molding with the sensor 70 as a core.

.. Foamed resin The foamed resin 4A is composed of a plurality of bubbles and a resin containing these bubbles, and is provided so as to fill the surrounding space of the sensor member 7A. At least a part of the foamed resin 4A shown in this example exists between the pair of winding portions 2a and 2b of the coil 2. That is, the reactor 1A is configured such that the foamed resin 4A has a corner R portion between a narrow space between the upper corner R portions 20 and 20 opposed to each other and a plane arranged opposite to each other inside the corner R portion 20. 20 and 20 in a narrower space (inner region, lower region than the upper corner R portion in FIG. 2). In this example, since the partition part 722 is inserted between the winding parts 2a and 2b, the presence area of the foamed resin 4A is a narrower space. More specifically, the foamed resin 4A is filled in a space surrounded by the outer peripheral surfaces of the pair of winding portions 2a and 2b that are arranged to face each other and the outer peripheral surface of the sensor member 7A (resin forming portion 72). As shown in FIG. 2, between one winding part 2a and one surface of the partition part 722, between the other winding part 2b and the other surface of the partition part 722, that is, on both sides of the partition part 722, respectively. Foamed resins 4A and 4A are provided. Each of the foamed resins 4A and 4A is mainly composed of an upper corner R portion 20 and a plane connected to the corner R portion 20 on the outer circumferential surface of one winding portion 2a of the coil 2 or the outer circumferential surface of the other winding portion 2b. And a space surrounded by a part of the outer peripheral surface of the protective portion 727 and one surface of the partition portion 722 in the outer peripheral surface of the resin molded portion 72 of the sensor member 7A.

The above space is substantially a closed space in the manufacturing process. By expanding the volume of the resin by expanding the resin in such a closed space, both of the foamed resins 4A and 4A are mainly filled in the space. Therefore, both of the foamed resins 4A and 4A have a shape substantially along the space. A part of the foamed resin 4A is interposed between the corner R portion 20 of the winding portions 2a and 2b and the protective portion 727 of the sensor member 7A, or between the turns of the winding portions 2a and 2b. Is acceptable. The foamed resin interposed between the turns is expected to contribute to the prevention of expansion and contraction of the winding portions 2a and 2b.

When the foamed resin expands in volume in the above-described closed space, the foamed resins 4A and 4A come into contact with both the coil 2 (winding portions 2a and 2b) and the sensor member 7A. Depending on the amount of expansion, it can be expected that the sensor member 7A is pressed against the coil 2 (winding portions 2a, 2b) in the space. Filling the space mainly with the foamed resins 4A and 4A makes it difficult to create a gap around the sensor 70, and also makes it easy to maintain the contact state between the coil 2 and the sensor member 7A. In particular, in this example, the foamed resins 4A and 4A are equally provided on both sides of the partition portion 722 of the sensor member 7A. Therefore, the sensor member 7A can uniformly contact each of the winding portions 2a and 2b by the foamed resins 4A and 4A that are uniformly volume-expanded. The foamed resin 4A in this example has a certain degree of adhesive force and is in close contact with the coil 2 and the sensor member 7A, and it is easier to maintain the contact state between the coil 2 and the sensor member 7A.

The size of the foamed resin 4A (filling volume, presence area along the partitioning part 722, etc.) can be in contact with both the coil 2 and the sensor member 7A, and is appropriately within a range where the surrounding space of the sensor 70 can be sufficiently filled. You can choose. In this example, the foamed resins 4 </ b> A and 4 </ b> A are present so as to reach substantially the entire length of the partition part 722, but may be configured to exist partway through the partition part 722. Of the above space, a region near the protective part 727 including the sensor 70 is a region where contact with the coil 2 is most desired. Therefore, it is preferable that at least the foamed resin 4 </ b> A exists without any gap.

... Constituent material of foamed resin The resin component of the foamed resin 4A is in contact with the coil 2, so that it has excellent electrical insulation and heat resistance against the maximum temperature of the coil 2 (150 ° C or higher, and further 180 ° C Above) is preferable. Since this resin component can come into contact with a liquid refrigerant or the like, it is preferable that the resin component has excellent resistance to the liquid refrigerant. Specific examples of the resin include PPS resin, PA resin such as nylon, and epoxy resin. These resins generally have a higher thermal conductivity than air. The foamed resin 4 </ b> A made of such resin comes into contact with the coil 2 and the sensor 70 (protection unit 727), so that heat from the coil 2 can be transmitted to the sensor 70 satisfactorily.

An unfoamed resin sheet 400 (FIG. 3) can be suitably used as a raw material for the foamed resin 4A. The resin sheet is easy to handle, can be easily cut into a desired shape, and is excellent in flexibility, so that it can be easily disposed at an arbitrary location and has excellent workability.

A commercially available product or a known product can be used as the unfoamed resin sheet. For example, if the thickness of the resin after foaming is 3 times or more, 4.5 times or more, and even 5 times or more than the thickness of the resin before foaming, the above-described coil 2 and sensor member 7A ( It is expected that sufficient contact with the sensor 70) and filling of the surrounding space of the sensor 70 can be achieved. Specifically, the expansion coefficient obtained by (thickness of resin after foaming / thickness of resin before foaming) is 3 or more, 4.5 or more, and 5 or more. When the expansion coefficient satisfies the above range, the thickness of the unfoamed resin sheet 400 is sufficiently thin (for example, 0.2 mm or less), and the gap W ₂ between the winding portions 2a and 2b (FIG. 2) Even in a narrow place, the resin sheets 400 and 400 and the partition part 722 of the sensor member 7A can be inserted simultaneously and easily, and the workability is excellent.

As the unfoamed resin sheet, one having an unfoamed resin layer and an adhesive layer can be used. In the case where the adhesive layer is provided, it can be firmly bonded to the coil 2 and the sensor member 7A, and in addition to the contact fixing of the sensor member 7A to the coil 2 side by volume expansion, strong fixing by the adhesive layer can be expected. In addition, when the adhesive layer is provided, even when the thickness of the unfoamed resin layer is thin, the foamed resin having a desired volume expansion by bonding and laminating a plurality of resin sheets with the adhesive layer 4A is provided. The thickness of the unfoamed resin sheet (including the thickness of the adhesive layer when an adhesive layer is provided) may be selected so that the volume after foaming becomes a predetermined size. If the unfoamed resin sheet itself has an adhesive force (to some extent), the adhesive layer may be omitted. If it is desired to firmly fix the sensor member 7A with the coil 2, an adhesive can be used separately.

... Manufacturing method 4A of foamed resins can be formed by the following processes, for example. An unfoamed resin sheet as a raw material of the foamed resin 4A is cut into a predetermined shape (rectangular in FIG. 3), and the resin sheets 400 and 400 are respectively disposed on the front and back surfaces of the partition portion 722 of the sensor member 7A. And resin sheet 400,400 and the partition part 722 of 7 A of sensor members are inserted between a pair of winding parts 2a and 2b. When the resin sheet 400 has an adhesive force or has an adhesive layer, the resin sheets 400 and 400 are not dropped from the sensor member 7A, and are easy to insert and excellent in workability. Thereafter, the foamed resin 4A can be formed by performing heat treatment necessary for foaming.

The heating temperature and holding time of the heat treatment may be appropriately selected according to the resin components and the like. For example, the heating temperature is about 100 ° C. or higher and 170 ° C. or lower. Use of a resin (sheet) having a low heating temperature and a short holding time is preferable because it can prevent thermal damage to the coil 2 and the magnetic core 3 (particularly, the resin mold portion 310m) during heat treatment. Further, by using a resin (sheet) that can be foamed at a low temperature in a short time, the productivity can be improved and the cost can be reduced.

In this example, the heat treatment for foaming can be combined with the heat treatment in the solidifying step of the side resin mold part 320m. That is, the resin sheets 400 and 400 and the sensor member 7A are arranged in the assembly after the resin component of the resin mold portion 320m is molded and before solidification, and the foaming of the resin sheets 400 and 400 and the solidification of the resin mold portion 320m are performed. Can be done simultaneously. Resin sheets 400, 400 and the like may be placed on the assembly obtained by solidifying the resin mold part 320m, and heat treatment for foaming may be separately performed.

(Reactor manufacturing method)
Reactor 1A includes, for example, the following preparation process, core part 310 manufacturing process, coil 2 and magnetic core (core part 310, core piece 32m) assembly process, side resin mold part 320m formation process, sensor member 7A and It can manufacture with the manufacturing method of a reactor provided with the arrangement | positioning process of the resin sheet 400, a solidification, and a foaming process. The outline of each process is as follows.

In the preparation step, the coil 2, the core pieces 31m and 32m, the sensor member 7A including the resin molding portion 72, and the unfoamed resin sheet 400 are prepared.

In the core component manufacturing process, a plurality of core pieces 31m are spaced apart and covered with a middle resin mold portion 310m, and the resin is also filled between the core pieces 31m and 31m, and includes a frame portion 315 and a gap portion 310g. The core component 310 is produced.

In the process of assembling the coil and magnetic core, the core covering portions of the core component 310 are inserted into the winding portions 2a and 2b of the coil 2, respectively, and the core pieces 32m and 32m are arranged so as to sandwich the frame portions 315 and 315. Assemble the ring to make a braid.

In the step of forming the side resin mold part, the exposed parts of the core pieces 32m, 32m of the assembly assembled in the above-described annular shape are covered with the constituent resin (unsolidified) of the side resin mold part 320m to produce a coated intermediate.

In the arrangement process of the sensor member and the resin sheet, the resin sheets 400 and 400 are arranged on the front and back surfaces of the partition part 722 of the sensor member 7A, respectively, and between the pair of winding parts 2a and 2b in the above-described covering intermediate, The partition part 722 and the resin sheets 400 and 400 are inserted simultaneously.

In the solidification and foaming step, the constituent resin of the side resin mold part 320m of the above-mentioned covering intermediate is solidified and the resin sheets 400 and 400 are foamed.

In addition, after forming the foamed resin 4A between the coil 2 and the sensor 70, the reactor 1A can assemble the core piece 32m and solidify the side resin mold part 320m. That is, the coil 2 is fixed by the foamed resin 4A after going through the preparation process, the core part 310 manufacturing process, the coil 2 and core part 310 assembly process, the sensor member 7A and the resin sheet 400 placement process, and the foaming process. The assembled process of the core component 310 and the core piece 32m, the formation of the side resin mold part 320m, and the solidification process can be performed.

(effect)
The reactor 1 </ b> A according to the first embodiment includes the foamed resin 4 </ b> A that has been volume-expanded during the manufacturing process, so that gaps that can occur around the sensor 70 can be reduced. Further, since the foamed resin 4A can sufficiently adhere to both the coil 2 and the sensor member 7A due to volume expansion, the foamed resin 4A can be used as a heat transfer path for transmitting the heat of the coil 2 to the sensor 70 of the sensor member 7A. . In particular, if the foamed resin has an adhesive force, the contact state between the coil 2 and the sensor member 7A can be firmly maintained. Depending on the arrangement state and expansion amount of the foamed resin 4A, the sensor 70 may be pressed against the coil 2 side by the foamed resin 4A. From this, the reactor 1A has a good contact state between the coil 2 and the sensor 70. Can be expected to be maintained. Therefore, even when the reactor 1A is not provided with a sealing resin and a case, even when the reactor 1A is used for an in-vehicle component or the like to which vibration can be applied, the foamed resin 4A that is superior in thermal conductivity to air is present around the sensor 70. By being present, the measurement accuracy can be improved and the temperature of the coil 2 can be measured satisfactorily. The reactor 1A can measure the temperature of the coil 2 with higher accuracy than when no sealing resin is provided and there is a lot of air around the sensor member 7A.

In particular, in the reactor 1A according to the first embodiment, the sensor 70 (protection unit 727) is arranged at least one of the winding portions 2a and 2b, preferably both corners R, by arranging the sensor 70 as a trapezoidal space 27A. A point that can contact the part 20 (contacts both in FIG. 2), at least a part of the foamed resin 4A and the partition part 722 exist between the winding parts 2a and 2b, and around the sensor 70 (protection part 727). The reactor 1A can accurately measure the temperature of the coil 2 from the point that the gap that can be generated can be reduced and the point that the trapezoidal space 27A can be easily maintained. In addition, in the reactor 1A, by using the sensor member 7A provided with the resin molded portion 72, it is easy to handle the sensor 70, place the sensor 70 on the coil 2, support and place the resin sheet 400, Excellent manufacturability.

[Modification 1-1]
In the first embodiment, the configuration in which the foamed resins 4A and 4A are equally provided on both sides of the partition portion 722 of the sensor member 7A has been described. In addition, if it can contact both the coil 2 and the sensor member 7A, the foamed resin 4A can be provided only on one side of the partition portion 722. In this case, for example, it is possible to use a thicker one than the thickness of the unfoamed resin sheet 400 used in the manufacturing process of the first embodiment. When the foamed resin 4A is interposed between one of the outer peripheral surfaces of the winding portions 2a and 2b of the coil 2 and one side of the partition portion 722, a gap that may occur around the sensor 70 is formed when there is no foamed resin 4A. It can be reduced in comparison. Depending on the volume expansion of the foamed resin, it can be expected that the partition portion 722 is pressed against the other winding portion. By this pressing, the partition portion 722 and the winding portion are in contact with each other, and this contact state can be maintained. From these facts, it is expected that in this embodiment, the physical quantity is transmitted from the winding part to the sensor 70 via the resin molding part 72 and the physical quantity can be measured satisfactorily.

Alternatively, the foamed resins 4A and 4A may be provided on both sides of the partition portion 722 with nonuniform sizes. In this case, the gap that may occur around the sensor 70 can be further reduced as compared with the case where there is no foamed resin 4A, and the partition portion 722 is wound from the side with the larger volume expansion of the foamed resin toward the smaller side. You can expect to be pressed against. This pressing can also be expected to contact the partition portion 722 and the winding portion as described above. Therefore, this form is also expected to be able to measure the physical quantity satisfactorily by transmitting the physical quantity to the sensor 70 via the resin molding part 72 from the winding part with which the partition part 722 is in contact.

[Modification 1-2]
In the first embodiment, the configuration in which the sensor member 7A includes the resin molding portion 72 that integrally includes the protection portion 727 and the partition portion 722 that cover the sensor 70 has been described. As another sensor member, it can be set as the form provided only with the part which covers the sensor 70. FIG. For example, a sensor tube such as a resin tube or a resin molded product like Embodiment 1 that does not have the partitioning part 722 and includes only the protection part 727 (see Embodiment 2), etc. Available to: Furthermore, it can be set as the form further equipped with the following sensor holders which hold | maintain this columnar sensor member. Examples of the sensor holder include a resin molded product in which a holding portion of a sensor member and a partition portion are integrally formed as described in Patent Document 1. In this embodiment, a columnar sensor member is assembled to the sensor holder and arranged at a predetermined position (in the first embodiment, the trapezoidal space 27A).

[Modification 1-3]
In the first embodiment, the structure in which the middle resin mold part 310m is formed and the side resin mold part 320m are formed in different stages has been described. In addition, a core part including the core piece 32m and the side resin mold portion 320m is used, and a total of four core parts including a pair of (inner side) core parts 310 and 310 and a pair of (outer side) core parts are assembled. be able to. In this form, each core part can be manufactured, and the shape of the object to be coated becomes simple, so that the productivity of the assembled part is excellent. In this embodiment, the assembly state can be firmly maintained by providing an engagement portion or the like in which the core components engage with each other.

In this mode, as described above, in addition to a mode including a total of four columnar core parts, the laminate including the core piece 31m housed in one winding part and the one core piece 32m are assembled in an L shape. In a form including a set of L-shaped core parts that are integrally held in the resin mold part, two laminates respectively stored in each winding part and one core piece 32m are assembled in a U shape to form a resin mold It is possible to adopt a form including a U-shaped core part integrally held in the part and one outer core part.

[Modification 1-4]
In the first embodiment, the configuration in which the reactor 1A is directly attached to the installation target has been described. In addition, it can be set as the form provided with the individual case which accommodates reactor 1A. Or it can be set as the form provided with an individual case and sealing resin with which it fills in an individual case. In these forms, mechanical protection of the reactor 1A and protection from the external environment can be achieved by an individual case or a sealing resin.

[Modification 1-5]
In the first embodiment, the configuration in which the magnetic core 3 includes the resin mold portions 310m and 320m that cover the core pieces 31m and 32m has been described. In addition, it can be set as the form provided with the interposed member interposed between the coil 2 and the magnetic core instead of the form which is not provided with the resin mold part, and the resin mold part. As the interposed member, a molded product made of an insulating material such as the above-described resin can be used. For example, the interposition member includes an inner interposition portion interposed between the winding portions 2a and 2b and a laminate including the plurality of core pieces 31m, an end surface of the winding portions 2a and 2b, and an inner end surface 32e of the core piece 32m. And an end intervening portion interposed between them. The inner interposition part is, for example, a cylindrical member, and the end interposition part is, for example, a flat plate like the frame part 315, and has a pair of through holes through which the laminate including the core piece 31m is inserted. The provided frame board member is mentioned. By providing the interposition member, the insulation between the coil 2 and the magnetic core can be enhanced.

[Embodiment 2]
With reference to FIG. 4, the reactor 1B of Embodiment 2 is demonstrated. A reactor 1B according to the second embodiment includes a coil 2 having a pair of winding portions 2a and 2b, a magnetic core 3 having portions disposed inside and outside the winding portions 2a and 2b, and a sensor member that measures a physical quantity of the reactor 1B. The point provided with 7B and the foamed resin 4B which contacts both the coil 2 and the sensor member 7B is the same as that of the reactor 1A of the first embodiment. The main difference between the reactor 1B and the first embodiment is in the form of the sensor member 7B and the location where the sensor 70 is disposed, and the other points are substantially the same. Hereinafter, the description will be focused on this difference, and the description of other configurations will be omitted.

(Reactor)
In the magnetic core 3 provided in the reactor 1B, the core piece 32m arranged outside the coil 2 as described above protrudes from the core piece 31m (FIG. 3) arranged inside the coil 2, and the inner end surface of the core piece 32m. Parallel to 32e, a counter surface 315c of the frame portion 315 of the middle resin mold portion 310m is provided. The facing surface 315c of the frame portion 315 is configured to be opposed to the end surfaces of the winding portions 2a and 2b and is a plane orthogonal to the axial direction of the winding portion. On the other hand, the winding 2w of each winding part 2a, 2b of the coil 2 is wound spirally. Therefore, in the state where the coil 2 and the magnetic core 3 are combined, the reactor 1B is a space sandwiched between the end surfaces of the winding portions 2a and 2b and the facing surface 315c of the frame portion 315, in this example, the winding portions 2a and 2b. An inclined space 27G corresponding to the inclination created by the turn at the end of 2b is provided.

In the reactor 1B shown in this example, a total of four inclined spaces 27G, ... are provided. Specifically, each of the inclined spaces 27G,... Is connected to the terminal fitting in one winding part 2a and is located at one side closer to the outside, and on the connecting part 2r side, and both winding parts 2a and 2b. Is one side closer to the inner side opposite to each other, on the connection side with the terminal fitting in the other winding part 2b, and one side closer to the inner side where both winding parts 2a and 2b face each other, on the coupling part 2r side. One place is provided near the outside of the winding part 2b.

In the reactor 1B of the second embodiment, the inclined space 27G is used as the location where the sensor 70 is disposed. Here, among the four inclined spaces 27G, a portion considered to be close to a portion where the temperature of the coil 2 is high, specifically, an inclined space closer to the inside on the connection side with the terminal fitting in the other winding portion 2b. 27G is an arrangement place of the sensor member 7B. It is good also as one place selected from other three places.

The opposing surface 315c of the frame portion 315 is a surface that intersects the axial direction of the winding portion non-orthogonally, and a parallel space or the like is provided between the end surface of each winding portion 2a, 2b and the opposing surface 315c of the frame portion 315. By providing this space, the sensor 70 can be placed.

The sensor member 7B provided in the reactor 1B of the second embodiment includes a sensor 70 and a resin molded portion 72. However, the resin molding part 72 of the sensor member 7 </ b> B does not have the partition part 722 and includes only the protection part 727 that covers the sensor 70. Therefore, the sensor member 7B has a cylindrical shape. Thus, the sensor member 7B can be accommodated in the above-described inclined space by adopting a small form including the sensor 70 and the protection portion 727. In FIG. 4, the wiring 78 (FIG. 1) is omitted for easy understanding.

The foamed resin 4B is interposed in an inclined space 27G sandwiched between the end surface of the winding portion 2b and the facing surface 315c of the frame portion 315. More specifically, as shown in FIG. 4, the foamed resin 4B is formed so that a part of the cylindrical sensor member 7B comes into contact with the facing surface 315c of the frame portion 315 and covers the other part of the sensor member 7B. Yes. That is, the foamed resin 4B is mainly interposed between the end surface of the coil 2 (winding portion 2b) and the sensor member 7B, and can sufficiently contact both the winding portion 2b and the sensor member 7b by volume expansion. In addition, a gap is hardly generated around the sensor 70. When the foamed resin 4B has a portion interposed between the sensor member 7B and the facing surface 315c of the frame portion 315, it can be expected that the sensor member 7B is pressed against the winding portion 2b by volume expansion.

(Reactor manufacturing method)
The manufacturing method described in the first embodiment can be used for manufacturing the reactor 1B of the second embodiment.

Here, the inclined space 27G extends in a direction orthogonal to both the axial direction of the coil 2 (winding portions 2a and 2b) and the parallel direction of the winding portions 2a and 2b (a direction perpendicular to the paper surface in FIG. 4). It is a space that tapers from one opening (opening in front of the paper surface in FIG. 4) toward the other opening (opening in the back of the paper surface). Therefore, when the sensor member 7B is inserted and disposed in the inclined space, the sensor member 7B can be sandwiched by the tapered portion, and the sensor member 7B can be easily positioned. Further, by this clamping, it is difficult for the sensor member 7B to be displaced at the time of foaming of the resin without the sensor holder or the like, and the reactor 1B in which the sensor member 7B (especially the sensor 70) is arranged at a predetermined position is provided. It can be manufactured with high accuracy and has excellent manufacturability. Since the sensor holder can be omitted, the number of parts can be reduced, and also from this point, the reactor 7B is excellent in manufacturability.

(effect)
Similarly to the reactor 1A of the first embodiment, the reactor 1B of the second embodiment can sufficiently generate the volume-expanded foamed resin 4B in close contact with both the coil 2 and the sensor member 7B, and can be generated around the sensor 70. The gap can be reduced. If the foamed resin has adhesive force, the contact state between the coil 2 and the sensor member 7B can be firmly maintained. Further, the reactor 1B can use a portion of the foamed resin 4B that is interposed between the end face of the coil 2 and the sensor member 7B as a heat transfer path for transmitting the heat of the coil 2 to the sensor 70. Therefore, even if the reactor 1B does not include the sealing resin and the case, or is used for a vehicle-mounted component, the temperature of the coil 2 can be measured with good accuracy.

In particular, the reactor 1B according to the second embodiment makes it easy to support the sensor member 7B by the foamed resin 4B sandwiched between the coil 2 and the frame portion 315 because the place where the sensor 70 is disposed is the inclined space 27G. Is easily maintained at a predetermined position, the reactor 1B can accurately measure the temperature of the coil 2. In addition, the reactor 1B is easy to position in the manufacturing process as described above, and in addition to being able to omit the sensor holder and being excellent in manufacturability, the dead space of the coil 2 can be used effectively and can be reduced in size.

Note that the configurations of the modified examples 1-3 to 1-5 can be applied to the reactor 1B of the second embodiment. When it is set as the form provided with an interposition member, it replaces with the frame part 315 as a facing member which comprises the inclined space 27G, and utilizes a part of above-mentioned frame board member arrange | positioned facing the inner end surface 32e of the core piece 32m. can do.

[Embodiment 3]
With reference to FIG. 5, the reactor 1C of Embodiment 3 is demonstrated. Reactor 1C of Embodiment 3 measures physical quantities of coil 2 having a pair of winding portions 2a and 2b arranged in parallel, magnetic core 3 having portions arranged inside and outside winding portions 2a and 2b, and reactor 1C. It is the same as that of the reactor 1A of Embodiment 1 in that the sensor member 7C is provided and the foamed resin 4C is in contact with both the coil 2 and the sensor member 7C. Further, the sensor member 7C is the same as the sensor member 7B of the reactor 1B of the second embodiment in that the sensor member 7C has a columnar shape including the sensor 70 and the protection unit 727. The main difference between the reactor 1C and the first embodiment is that the arrangement location of the sensor 70 and the heat radiating plate 6 are provided, and the other points are substantially the same. Hereinafter, the description will be focused on this difference, and the description of other configurations will be omitted.

(Reactor)
The reactor 1 </ b> C includes a heat radiating plate 6 on which an assembly including the coil 2 and the magnetic core 3 is placed. As the heat radiating plate 6, a plate made of a material having excellent thermal conductivity can be used as appropriate. As the constituent material of the heat radiating plate 6, lightweight aluminum, aluminum alloy, or the like having high thermal conductivity can be suitably used. Other metals include magnesium and magnesium alloys. In addition, if a non-metallic inorganic material such as alumina is used, the insulation between the coil 2 is excellent.

As the heat radiating plate 6, a flat plate having a size equal to or larger than the installation surface of the reactor 1C can be suitably used so that the reactor 1C can be supported. The installation surface of the reactor 1C in this example is mainly the installation surface (lower surface) of the winding portions 2a and 2b of the coil 2 and the side resin mold portion 320m (FIG. 1) that covers the core piece 32m (FIG. 1) of the magnetic core 3. ), The flat plate having a size larger than the total area is suitable for the heat radiating plate 6. In addition, the heat sink 6 can be provided with a bolt hole (not shown) through which a bolt (not shown) to be fixed to the installation target is inserted. In addition, the heat radiating plate 6 can be provided with an adhesive resin layer (not shown) for fixing the installation surface of the coil 2 and the installation surface of the magnetic core 3.

Both winding parts 2a and 2b of the coil 2 provided in the reactor 1C are provided with the corner R part 20 as described above. Therefore, it replaces with the virtual surface 200 which connects the outer peripheral surface of winding part 2a, 2b in a parallel direction, and the angle | corner arrange | positioned facing in a pair of winding part 2a, 2b by arrange | positioning one plane of the heat sink 6 An upward trapezoidal space 27 </ b> C is formed by the R parts 20, 20 and the heat radiating plate 6 (see also FIG. 2). The reactor 1 </ b> C uses a trapezoidal space 27 </ b> C provided on the lower side as a location where the sensor 70 is disposed.

The foamed resin 4C is interposed in the trapezoidal space 27C. Specifically, the foamed resin 4C is formed by contacting a part of the cylindrical sensor member 7C with the corner R portions 20 and 20 disposed opposite to each other in the winding portions 2a and 2b as shown in FIG. Space, that is, the closed space surrounded by the corner R portions 20 and 20, the sensor member 7C, and the heat radiating plate 6, is mainly filled and comes into contact with both the coil 2 and the sensor member 7C. Further, the foamed resin 4C can be in close contact with the coil 2 and the sensor member 7C by the volume expansion of the foamed resin filled in the trapezoidal closed space. Depending on the amount of expansion, it can be expected that the foamed resin 4C presses the sensor member 7C (particularly the sensor 70) against the coil 2 side (pushes it upward). From these things, the foamed resin 4C can maintain the state which contacted both the coil 2 and the sensor member 7C favorably. In addition, by being supported by the foamed resin 4C, the sensor member 7C (particularly the sensor 70) can contact at least one of the winding portions 2a and 2b, preferably both corner R portions 20 and 20. FIG. 5 illustrates a state in which both corner R portions 20 and 20 are in contact with the sensor member 7C. A part of the foamed resin 4C is allowed to intervene between the coil 2 and the sensor member 7C.

(Reactor manufacturing method)
The manufacturing method described in the first embodiment can be used for manufacturing the reactor 1C of the third embodiment. In particular, an unfoamed resin sheet is disposed at a predetermined position on the heat radiating plate 6, and a sensor member 7C is disposed thereon. The covering intermediate obtained through the molding process of the side resin mold portion is placed so that the sensor member 7C is interposed between the winding portions 2a and 2b. When the resin sheet has adhesiveness, the sensor member 7C is not easily displaced when the covering intermediate is placed, and it does not need to be separately supported, and the workability is excellent. After placing the covering intermediate, the constituent resin of the side resin mold portion is solidified and the resin sheet is foamed.

(effect)
Similarly to the reactor 1A of the first embodiment, the reactor 1C of the third embodiment can generate the volume expanded resin 4C sufficiently close to both the coil 2 and the sensor member 7C, and can be generated around the sensor 70. The gap can be reduced. In particular, if the foamed resin has an adhesive force, the contact state between the coil 2 and the sensor member 7C can be firmly maintained. Furthermore, since the reactor 1C has a trapezoidal space 27C that is a closed space by the heat radiating plate 6 at the place where the sensor 70 is disposed, the above-mentioned closed space is sufficiently filled with the foamed resin. The contact area with 4C tends to increase, and foamed resin tends to exist around the sensor 70. Therefore, it is easy to use the foamed resin 4C for the heat transfer path. Even if such a reactor 1C does not include a sealing resin and a case, or is used for an in-vehicle component, the temperature of the coil 2 can be measured with good accuracy.

The sensor member 7C can be held by a sensor holder (not shown), or can be provided with a partition 722 like the sensor member 7A. In the form including the partition part 722, in addition to providing the foamed resin 4 </ b> C in the trapezoidal space 27 </ b> C, for example, in the same manner as in the first embodiment, the form is provided with foam resin on both the front and back surfaces of the partition part 722. it can. In this case, a larger area of the protection portion 727 can be covered with the foamed resin, and further reduction of the gap that may occur around the sensor member 7C and improvement in thermal conductivity from the coil 2 can be expected. In the embodiment including the partition portion 722, the configuration of Modification 1-1 can be applied.

In addition, the configurations of the modified examples 1-3 to 1-5 can be applied to the reactor 1C of the third embodiment.

The present invention is not limited to these exemplifications, but is defined by the scope of the claims, and is intended to include all modifications within the scope and meaning equivalent to the scope of the claims. For example, a reactor including a coil having only one winding part and a magnetic core called an EE type core or an EI type core can be used. In this case, for example, a configuration in which the sensor and the foamed resin are interposed between the outer peripheral surface of the coil and the inner peripheral surface of a portion of the magnetic core surrounding the outer periphery of the coil can be employed.

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 used as a component of a power conversion device.

1A, 1B, 1C Reactor 2 Coil 2a, 2b Winding part 2r Coupling part 2w Winding 20 Corner R part 200 Virtual surface 27A, 27C Trapezoidal space 27G Inclined space connecting outer peripheral surfaces of a pair of winding parts 3 Magnetic core 31m, 32m Core piece 32e Inner end face 310 Core part 310m Middle resin mold part
310g Gap part 315 Frame part 315h Through hole
315c Face of the frame portion facing the coil 316 Projection 317 Projection 318 Locking portion 319 Partition plate 320m Side resin mold portion 325 Mounting portion 325h Bolt hole 4A, 4B, 4C Foamed resin 400 Unfoamed resin sheet 6 Heat sink 7A , 7B, 7C Sensor member 70 Sensor 72 Resin molding part 78 Wiring 727 Protection part 722 Partition part 725 Base part

Claims (8)

1. A coil having a winding portion formed by winding a winding;
   A magnetic core having a portion disposed inside and outside the winding portion;
   A sensor for measuring the physical quantity of the reactor;
   A reactor comprising a foamed resin that contacts both the coil and the sensor.
2. The coil includes a pair of winding portions whose end face shape is a rectangular shape having a corner R portion, and the pair of winding portions are arranged in parallel so that the axes of the winding portions are parallel to each other,
   The sensor is supported by the corner R portion,
   The reactor according to claim 1, wherein a part of the foamed resin is provided between the pair of winding parts.
3. The reactor according to claim 2, wherein a part of the foamed resin is provided in a region between the pair of winding portions and inside the corner R portion.
4. A resin molding part provided integrally with a protection part covering the sensor and a partition part arranged between the pair of winding parts;
   The reactor according to claim 2 or 3, wherein a part of the foamed resin is provided in a space surrounded by the wound portion and an outer peripheral surface of the resin molded portion.
5. Having a facing member disposed to face the end face of the winding portion;
   The sensor is disposed in a space sandwiched between an end surface of the winding part and the opposing member,
   The reactor according to claim 1, wherein a part of the foamed resin is provided between an end face of the winding portion and the sensor.
6. A heat sink for placing a combined body having the coil and the magnetic core,
   The coil includes a pair of winding portions whose end face shape is a rectangular shape having a corner R portion, and the pair of winding portions are arranged in parallel so that the axes of the winding portions are parallel to each other,
   The sensor is disposed in a trapezoidal space formed by the corner R portion disposed opposite to the pair of winding portions and the heat radiating plate,
   The reactor according to claim 1, wherein at least a part of the foamed resin is provided in the trapezoidal space.
7. The reactor according to any one of claims 1 to 6, wherein the magnetic core includes a core piece including a soft magnetic material and a resin mold portion that covers the core piece.
8. The reactor according to any one of claims 1 to 7, wherein the sensor includes a thermistor.

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