WO2016143729A1 - Reactor - Google Patents

Abstract

Provided is a reactor that has excellent productivity and facilitates the filling, with a resin, of a space formed between a plurality of core pieces. The reactor is provided with: a coil that has a winding portion; a magnetic core that is formed by combining the core pieces and a gap material interposed between the core pieces and has a portion disposed inside the winding portion; an interposed member that is interposed between the inner surface of the winding portion and the magnetic core and holds the core pieces in a prescribed position; and a resin mold portion that unifies the coil and the magnetic core. The interposed member is provided with a guide portion that ensures a space between the core pieces and performs positioning of the core pieces, and a channel that, during molding of the resin mold portion, allows an unsolidified constituent resin of the resin mold portion to flow to the core pieces. The gap material is formed using said constituent resin of the resin mold portion.

Description

Reactor

The present invention relates to a reactor used for a vehicle-mounted DC-DC converter or a power converter component mounted on a vehicle such as a hybrid vehicle.

2. Description of the Related Art Magnetic parts including a coil such as a reactor or a motor wound with a winding and a magnetic core disposed inside and outside the coil to form a closed magnetic path are used in various fields. As such a magnetic component, for example, Patent Document 1 discloses a reactor used for a circuit component of an in-vehicle converter.

Patent Document 1 discloses a mold type reactor in which most of the outer periphery of the reactor is molded with resin. The reactor includes a bobbin (intervening member) interposed between the coil and the magnetic core, and the intervening member is provided with a guide portion that secures a gap (interval) between adjacent partial cores (core pieces). It has been. Patent Document 1 describes that the space between the core pieces is filled with mold resin.

JP 2014-003125 A

However, in the reactor of patent document 1, the part arrange | positioned between a coil and a core piece among the interposed members is comprised by the flat plate arrange | positioned over several core pieces, and it is a core from the outside of a reactor. There is a possibility that the space between the pieces cannot be reliably filled with resin.

The present invention has been made in view of the above circumstances, and one of the objects of the present invention is to provide a reactor that is easily filled with a resin in an interval formed between a plurality of core pieces and has excellent productivity. There is.

The reactor which concerns on 1 aspect of this invention combines the coil which has a winding part, the gap material interposed between several core pieces and each core piece, and has the magnetic part which has a part arrange | positioned in the said winding part. A core, an interposition member interposed between the inner surface of the winding part and the magnetic core, and holding the plurality of core pieces in a predetermined position; a resin mold part for integrating the coil and the magnetic core; . The interposition member is provided with a guide part for positioning each core piece by securing a space between the plurality of core pieces, and an unsolidified constituent resin of the resin mold part when molding the resin mold part. A flow path for allowing the plurality of core pieces to flow in between. The gap material is formed of a constituent resin of the resin mold part.

The above reactor can be easily filled with a resin in an interval formed between a plurality of core pieces, and is excellent in productivity.

The outline of the reactor which concerns on Embodiment 1 is shown, the upper figure is a perspective view, and the lower figure is an enlarged view of the part enclosed with the dashed-dotted line of the upper figure. 1 is a schematic exploded perspective view of a reactor according to a first embodiment. It is a perspective view which shows the interposed member with which the reactor which concerns on Embodiment 1 is provided. It is a perspective view which shows the interposition member with which the reactor which concerns on Embodiment 2 is provided.

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

(1) The reactor which concerns on embodiment of this invention combines the coil which has a winding part, several core pieces, and the gap material interposed between each core piece, and the part arrange | positioned in the said winding part A magnetic core, an interposed member interposed between the inner surface of the winding part and the magnetic core, and holding the plurality of core pieces in a predetermined position; and a resin that integrates the coil and the magnetic core A mold part. The interposition member is provided with a guide part for positioning each core piece by securing a space between the plurality of core pieces, and an unsolidified constituent resin of the resin mold part when molding the resin mold part. A flow path for allowing the plurality of core pieces to flow in between. The gap material is formed of a constituent resin of the resin mold part.

The reactor includes, for example, a plurality of inner core pieces arranged in the winding portion among the plurality of core pieces in the interposed member, and the inner core piece and the interposed member arranged in the winding portion. ⇒ The assembled core is assembled with the outer core piece placed outside the winding part of the magnetic core in the assembly. ⇒ The resin mold part is not solidified by placing the assembly in the mold. Can be manufactured by the procedure of filling and solidifying.

The above reactor is arranged along the guide portion when arranging the plurality of core pieces on the interposition member, so that the interval between the adjacent core pieces is secured and the relative positioning of each core piece is accurately performed. it can. Therefore, in the production of the assembly in the manufacturing process of the reactor, the plurality of inner core pieces arranged on the interposition member can be handled in a state where the predetermined positions of the respective inner core pieces are held, so that the workability is excellent. Moreover, it is easy to handle as a combined body, and it is easy to arrange in a mold and has excellent workability. When the unmolded component resin of the resin mold portion is filled in the mold in which the assembly is arranged, the unsolidified component resin flows between the plurality of core pieces, and a gap having a width corresponding to the interval between the core pieces. A material is formed. At this time, since the flow path is formed in the interposed member, the resin can surely flow into between the core pieces along the flow path. At the time of molding of the resin mold portion, a gap material between the core pieces can be formed, and the outer periphery of the coil and the outer periphery of each core piece (magnetic core) can be covered with resin, so that the coil and the magnetic core are integrated. be able to. Therefore, for example, the core piece and the gap material can be fixed in advance with an adhesive or the like, and the work of individually molding the core piece and the coil with resin can be simplified, and the reactor productivity is excellent. .

The above reactor does not cause an increase in the number of parts because the interposed member is provided with a guide portion and a flow path. In addition, it is possible to prevent the relative positions of the inner core pieces and the relative positions of the magnetic core and the coil from being shifted when the resin mold portion is filled with the unsolidified constituent resin.

(2) As an example of the reactor described above, the flow path is formed on at least one of the inner peripheral surface and the outer peripheral surface of the interposed member from an end portion along the axial direction of the winding portion of the interposed member inward. The form provided with the groove part formed toward the direction is mentioned.

According to the above configuration, the non-solidified resin of the resin mold part easily flows into between the core pieces. In addition, since the unsolidified component resin of the resin mold part flows into between the interposed member and the core piece, or between the interposed member and the coil, the contact between the core piece (magnetic core) and the resin mold part is ensured. The area and the contact area between the coil and the resin mold portion can be increased. Therefore, it is easy to improve the bonding strength between the coil and the magnetic core via the resin mold part.

(3) As an example of the reactor, the flow path may include a through hole that penetrates from the outer surface to the inner surface of the interposition member.

According to the above configuration, the non-solidified resin of the resin mold part easily flows into between the core pieces. In addition, since the resin mold part is fitted inside and outside of the interposed member through the through hole, the bonding strength between the core piece (magnetic core) and the resin mold part and the bonding strength between the coil and the resin mold part are increased. Easy to improve.

(4) As an example of the reactor described above, the interposition member inserts a plurality of inner core pieces arranged in the winding portion among the plurality of core pieces from a direction orthogonal to the axial direction of the winding portion. The insertion path is provided, and the flow path may be provided on a different surface from the surface on which the insertion hole is provided.

According to the above configuration, since the plurality of inner core pieces can be individually arranged along the guide portion with respect to the interposition member, it is easy to insert each inner core piece into a predetermined position of the interposition member. Relative positioning can be performed with higher accuracy. In addition, since the flow path is provided on a different surface from the insertion hole, an appropriate flow path can be formed without being affected by the insertion hole, and the resin can be appropriately distributed between the core pieces along the flow path. Can flow in.

(5) As an example of the above-described reactor, the coil includes a pair of winding portions arranged side by side, and the interposed member includes the winding of the plurality of core pieces for each of the pair of winding portions. The form which hold | maintains all the several inner core pieces arrange | positioned in a rotation part integrally is mentioned.

According to the above configuration, since all the inner core pieces can be handled in a state of being integrated and held in place, the workability is further improved.

(6) As an example of the reactor described above, the coil includes a pair of winding parts arranged side by side, and the magnetic core includes an outer core base disposed outside the winding part, and the outer core base. A pair of projecting portions that protrude and are respectively disposed in the winding portion, and a U-shaped outer core piece formed integrally with the projecting portion of the outer core piece, the winding portion of the interposition member The form inserted from the edge part along the axial direction of this is mentioned.

According to the above configuration, in the production of the assembly in the process of manufacturing the reactor, the relative positioning of the core pieces is further increased by inserting the protruding portions of the U-shaped outer core pieces from both ends of the interposition member. Can be accurate. In addition, since the assembly can be handled as an integrated object while maintaining predetermined positions (positions of the core pieces, positions of the core pieces (magnetic core) and the coil) of the constituent members of the reactor, the workability is excellent.

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

<Embodiment 1>
A reactor 1 according to Embodiment 1 will be described with reference to FIGS. 1 to 3.

[Reactor]
-Overall structure The reactor 1 of Embodiment 1 is arrange | positioned in the coil 2 which has the winding parts 2a and 2b formed by helically winding the coil | winding 2w, and the winding parts 2a and 2b, as shown in FIG. A magnetic core 3 having a portion to be formed, an interposition member 5 interposed between the inner surfaces of the winding portions 2a and 2b and the magnetic core 3, a resin mold portion 6 for integrating the coil 2 and the magnetic core 3, and . The magnetic core 3 includes a plurality of inner core pieces 31m,... That are arranged entirely inside the winding portions 2a, 2b, and outer core pieces 32m, 32m having portions arranged outside the winding portions 2a, 2b. And gap members 31g,... Interposed between the inner core pieces 31m and 31m and between the inner core piece 31m and the outer core piece 32m. In the reactor 1 of the first embodiment, the interposition member 5 secures intervals between the plurality of core pieces 31m,..., 32m, 32m and positions each core piece 31m,. One of the features is that the resin mold portion 6 has a configuration in which unsolidified constituent resin flows in at intervals between 31 m,..., 32 m, 32 m. Hereinafter, each configuration will be described in detail. In the following description, the installation side when the combination 10 including the coil 2 and the magnetic core 3 is installed is the lower side, and the opposite side is the upper side.

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

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

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

-Magnetic core As shown in FIG. 2, the magnetic core 3 includes a plurality of columnar inner core pieces 31m,..., A pair of U-shaped outer core pieces 32m, 32m, and a plurality of intervening core pieces. (See FIG. 1). The inner core pieces 31m,... Are magnetic pieces that are entirely disposed within the winding portions 2a, 2b, and the outer core pieces 32m, 32m are magnetic pieces having portions that are disposed outside the winding portions 2a, 2b. That is. The outer core pieces 32m and 32m may have a portion partially disposed in the winding portions 2a and 2b. In this example, the outer core pieces 32m and 32m are outside the winding portions 2a and 2b. And a portion disposed in the winding portions 2a and 2b. The outer core pieces 32m, 32m are arranged so that the U-shaped openings face each other, and the inner core pieces 31m,... Are arranged side by side (in parallel) between the outer core pieces 32m, 32m. In FIG. 2, there is a gap between the inner core pieces 31m,..., But the gap resin 31g is filled by filling the gap between the inner core pieces 31m,. ,... (See FIG. 1) are formed. In this example, the gap resin 31g is also formed by filling the gap between the inner core piece 31m and the outer core piece 32m opposed thereto with the constituent resin of the resin mold portion 6. With this arrangement, the magnetic core 3 is assembled in an annular shape, and forms a closed magnetic path when the coil 2 is excited.

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

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

Further, the lower surface of the outer core base portion 321 of the U-shaped outer core pieces 32m, 32m protrudes from the lower surface of the inner core piece 31m, and when the coil 2 and the magnetic core 3 are assembled, the lower surface of the outer core base portion 321. Is flush with the lower surface of the coil 2. That is, the installation surface of the combined body 10 of the coil 2 and the magnetic core 3 is configured by one surface (lower surface) of the coil 2 and one surface of the outer core piece 32m of the magnetic core 3 (lower surface of the outer core base portion 321). Therefore, the reactor 1 is configured such that the combined body 10 is stably disposed on an installation target (not shown) such as a cooling base, and a part of the magnetic core 3 in addition to the coil 2 is also in contact with the installation target. Increases heat dissipation.

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

.. Gap material The gap material 31g is formed by filling a gap formed between the core pieces 31m,..., 32m, 32m with a constituent resin of the resin mold portion 6 described later. The gap material 31g will be described in detail later in the description of the reactor manufacturing method.

Interposition member The interposition member 5 is interposed between the inner surface of the winding portions 2a and 2b and the core portion disposed in the winding portions 2a and 2b of the magnetic core 3, and the coil 2 and the magnetic core 3 It is a member that insulates the gap. Here, a pair of interposition members 5 and 5 are individually arranged with respect to each of the winding parts 2a and 2b. Since a pair of interposition members 5 and 5 are the same shape, below, one interposition member 5 arrange | positioned with respect to one winding part of winding part 2a, 2b is demonstrated. The interposition member 5 includes a storage part 51, a guide part 52, and a flow path 53. Hereinafter, each configuration of the interposition member 5 will be described in detail mainly with reference to FIGS.

..Storage part The storage part 51 has a substantially rectangular tube-like shape, and has an insertion hole 51a in a region excluding both ends of the upper surface, and a member for inserting and storing a plurality of inner core pieces 31m,. It is. The storage portion 51 has insertion holes 51b and 51b at both ends, and is a member for inserting and storing one protruding portion 322 of the outer core piece 32m from the insertion holes 51b and 51b. The housing 51 is integrally formed so as to be able to house all of the inner core pieces 31m,... And the protruding portion 322 of the outer core piece 32m. The storage 51 includes an annular strip at both ends, four U-shaped strips provided at equal intervals between the annular strips, and the annular strip and the four U-shaped strips on each side surface. Three linear pieces to be connected, and one linear piece to connect the annular strip and the four U-shaped strips on the bottom surface. The annular strip is provided so that the protruding portion 322 of the outer core piece 32m is inserted and housed and becomes an annular portion 51c surrounding the entire circumference of the protruding portion 322. The U-shaped strip is provided corresponding to the number of the plurality of inner core pieces 31m,. In this example, four U-shaped strips are provided so as to be arranged between and at both ends of the three inner core pieces 31m. The linear piece arranged on each side surface is provided corresponding to the flow path 53 described later. The linear pieces arranged on the bottom surface are provided so that the inner core pieces 31m,... Housed in the housing portion 51 are not dropped or displaced.

The inner surface of the storage part 51 is shaped to match the shape of the inner core piece 31m, and the corners other than the insertion hole 51a formed on the upper side are substantially rounded along the corners of the outer peripheral surface of the inner core piece 31m. It has been. The thickness between the inner surface and the outer surface of the storage portion 51 is substantially the same as the gap between the outer surface of the inner core piece 31m and the inner surface of the winding portion, and the inner core pieces 31m,. It is mentioned that it is a grade which can insert and arrange the interposed member 5 in a winding part in the state inserted from 51a.

.. Guide part The guide part 52 protrudes inward of the storage part 51, and secures an interval between the plurality of inner core pieces 31m,... And an interval between the inner core piece 31m and the outer core piece 32m, It is a member for positioning each core piece 31m, ..., 32m. In this example, the guide portion 52 is a U-shaped ridge extending from the insertion hole 51 a of the storage portion 51 along both side surfaces and the lower surface, and corresponds to a part of the U-shaped strip of the storage portion 51. That is, in this example, the four guide portions 52 are integrally formed on the inner surface of the storage portion 51.

The guide portion 52 is formed so that the inner core pieces 31m,... And the outer core piece 32m can be arranged at desired positions. The thickness of the guide portion 52 (the axial thickness of the winding portion) corresponds to the thickness of the gap material 31g (see FIG. 1). Therefore, the inner core pieces 31m,... Can be positioned by simply inserting the inner core pieces 31m,... From the insertion hole 51a of the storage portion 51 along the guide portion 52, and the inner core pieces 31m,. ... a gap corresponding to the thickness of the gap material 31g can be formed. In other words, by inserting the inner core pieces 31m,... Into the storage part 51 along the guide part 52, the positioning of the inner core pieces 31m,. The plurality of inner core pieces 31m,... Can be stored at one time along the guide portion 52, so that the storing operation is easy to perform.

Further, the end surface of the protruding portion 322 is held against the guide portion 52 at the end by simply inserting the protruding portion 322 of the outer core piece 32m into the annular portion 51c from the insertion hole 51b of the storage portion 51, so that the outer surface The core piece 32m can be positioned. That is, the inner core pieces 31m,... And the protruding portions 322 of the outer core pieces 32m are inserted from the insertion holes 51a, 51b, 51b of the storage portion 51, respectively, so that the guide portions 52 cause the core pieces 31m,. , 32m, 32m can be positioned.

The interval between the core pieces 31m, ..., 32m, 32m is more stable and easily secured as the contact area between the inner core piece 31m or the protruding portion 322 and the guide portion 52 increases. However, if the protruding area of the guide portion 52 is increased in order to increase the contact area between the inner core piece 31m or the protruding portion 322 and the guide portion 52, the cross-sectional area of the gap between the core pieces decreases. If it does so, the filling amount of the non-solidified constituent resin of the resin mold part 6 with which it fills between each inner core piece will decrease, and crossing of the gap material 31g (refer FIG. 1) formed with the constituent resin of the resin mold part 6 will be carried out. The area becomes smaller. When the filling amount of unsolidified constituent resin in the resin mold part 6 filled between the core pieces decreases, the area where the core pieces are fixed by the resin mold part 6 is reduced, so that the core pieces are firmly fixed. There is a possibility that each core piece may vibrate when the reactor 1 is operated. For this reason, the guide portion can ensure a space between the core pieces and the cross-sectional area of the gap material 31g formed by the constituent resin of the resin mold portion 6 is 50% or more of the cross-sectional area of the inner core piece 31m. It is preferable to adjust the protrusion amount of 52. The cross-sectional area of the gap material 31g formed by the constituent resin of the resin mold part 6 is 60% or more, further 70% or more, particularly 80% or more of the cross-sectional area of the inner core piece 31m.

In this example, the guide part 52 is continuously formed in a U-shape in the circumferential direction of the inner surface of the storage part 51. However, if the core part 31m, ..., 32m can be positioned by the guide part 52, the guide part 52 can be positioned. The guide part may protrude intermittently.

.. Flow path The flow path 53 is a gap between each of the core pieces 31m, ... 32m formed by the guide part 52, when the resin mold part 6 to be described later is molded, the resin resin of the resin mold part 6 that has not been solidified. It is a space that flows in. In this example, the flow path 53 includes a groove portion 53 d formed on the inner peripheral surface and the outer peripheral surface of the storage portion 51, and a through hole 53 h formed on the side surface of the storage portion 51. By the combination of the groove 53d and the through hole 53h, the unsolidified constituent resin of the resin mold portion 6 can be efficiently allowed to flow into the gaps between the core pieces 31m,.

The molding of the resin mold portion 6 will be described in detail in the description of the manufacturing method of the reactor later. The assembly 10 in which the coil 2, the magnetic core 3, and the interposition member 5 are assembled is placed in a mold, and the resin mold 6 is molded. This is done by filling and solidifying the unsolidified constituent resin of the part 6 in the mold.

In this example, the groove 53 d includes a lateral groove 53 dx formed on the outer peripheral surface of the storage portion 51 from the insertion hole 51 b toward the inside in the axial direction of the winding portion, and an insertion hole 51 a on the inner peripheral surface of the storage portion 51. Vertical groove portion 53dy formed from the bottom to the bottom. By providing the lateral groove portion 53dx, the unsolidified constituent resin of the resin mold portion 6 can easily flow into between the core pieces 31m,. The filling of the unsolidified component resin into the mold is usually performed from the upper side of the mold (the upper side of the combined body 10). Therefore, by providing the vertical groove portion 53dy, the unsolidified constituent resin can easily flow more efficiently between the core pieces 31m, ... 32m.

By providing the through-hole 53h, the unsolidified constituent resin of the resin mold portion 6 can easily flow into between the core pieces 31m, ... 32m. In particular, by providing the through-hole 53h formed subsequent to the lateral groove 53dx, the unsolidified constituent resin is more likely to flow into between the core pieces 31m,. In addition, by providing the through hole 53h, it is possible to degas from the through hole 53h when the unsolidified constituent resin is filled, and the resin mold portion 6 can be easily degassed.

By providing the flow path 53 such as the groove 53d and the through-hole 53h, the unmolded constituent resin of the resin mold part 6 can be disposed between the interposed member 5 and the core pieces 31m,... 32m, or between the interposed member 5 and the coil 2. It is possible to reliably flow in between. Therefore, the contact area between each of the core pieces 31m,... 32m (magnetic core 3) and the resin mold part 6 and the contact area between the coil 2 and the resin mold part 6 can be increased. Therefore, the bonding strength between the coil 2 and the magnetic core 3 through the resin mold portion 6 can also be improved.

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

-Resin mold part The resin mold part 6 is provided so that the outer periphery of the coil 2 and the outer periphery of the magnetic core 3 containing the outer core pieces 32m and 32m may be covered as shown in FIG. Between the two. That is, the resin mold portion 6 integrates the coil 2 and the magnetic core 3 and also ensures insulation between the coil 2 and the magnetic core 3. Further, as shown in the lower diagram of FIG. 1, the constituent resin of the resin mold portion 6 is filled in the gaps between the plurality of core pieces 31 m,... 32 m formed by the guide portion 52 described above. A gap material 31g interposed between the core pieces is formed by the constituent resin of the resin mold portion 6.

In this example, the resin mold portion 6 is provided so that a part of the upper surface of the coil 2 and the lower surface of the outer core base portion 321 of the coil 2 and the outer core piece 32m are exposed to the outside without being covered. By doing so, when the reactor 1 is in operation, heat can be dissipated even if the coil 2 and the magnetic core 3 generate heat by energization, so that heat dissipation is excellent.

As the resin constituting the resin mold part 6, for example, a thermoplastic resin such as PPS resin, PTFE resin, LCP, PA resin (nylon 6, nylon 66, etc.), PBT resin, ABS resin or the like can be used. In addition, thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins can be used. Unsaturated polyester is advantageous in that it is difficult to break and is inexpensive. In addition, these resins may contain ceramic fillers such as alumina and silica to improve the heat dissipation of the resin mold portion 6. Further, when the constituent resin of the interposing member 5 and the constituent resin of the resin mold portion 6 are the same resin, the interposition member 5 and the resin mold portion 6 are excellent in integrity.

[Reactor manufacturing method]
The reactor 1 having the above-described configuration is, for example, a plurality of inner core pieces 31m,... Stored in the storage unit 51 are arranged in the winding unit to form a assembly. The outer core piece 32m to be arranged is assembled to form the combined body 10 ⇒The combined body 10 is disposed in the mold, and the resin mold part 6 is filled and solidified with the unsolidified constituent resin. Can do.

-Production of assembly First, as shown in FIG. 2, several inner core pieces 31m and ... are inserted in the accommodating part 51 of the interposition member 5 from the upper insertion hole 51a. At this time, each inner core piece 31m,... Is inserted along the guide portion 52 formed in the storage portion 51, so that each inner core piece 31m,... Is positioned and each inner core piece 31m, 31m is positioned. A gap corresponding to the thickness of the gap material 31g is formed therebetween. Then, the plurality of inner core pieces 31m,... Housed in the housing part 51 are inserted into the respective winding parts 2a, 2b of the coil 2 to form a braid.

-Production of union Next, a pair of outer core pieces 32m, 32m are assembled to the above-mentioned assembly to form an union 10. The outer core pieces 32m and 32m are inserted into the storage portion 51 of the interposition member 5 through the insertion holes 51b and 51b at both ends. At this time, since the end surfaces of the protrusions 322 and 322 are abutted against the guide part 52 at the end formed in the storage part 51, the protrusions 322 and 322 are positioned in the winding parts 2a and 2b. It is arranged with. The combined body 10 can be handled as an integral body in which the core pieces 31m,... 32m, 32m are positioned by the interposition member 5.

The winding portions 2a and 2b are preferably held in a state of being positioned with respect to the interposing members 5 and 5 by a jig (not shown). In addition, a positioning portion for positioning the winding portions 2a and 2b is provided on the interposing members 5 and 5, and the winding portions 2a and 2b are positioned with respect to the interposing members 5 and 5 by this positioning portion. It may be held.

-Formation of resin mold part The said assembly 10 is arrange | positioned in a metal mold | die, and the resin which is not solidified of the resin mold part 6 is filled in a metal mold | die. The unsolidified constituent resin filled in the mold covers the outer periphery of the coil 2 and the outer periphery of the magnetic core 3, and reaches the gap between the coil 2 and the magnetic core 3. The unsolidified constituent resin flows and fills along the flow path 53 provided in the interposition member 5 up to the gaps formed between the plurality of core pieces 31m,. In this state, by solidifying the constituent resin, the coil 2 and the magnetic core 3 are integrated, and the gap material 31g interposed between the core pieces is formed.

[Main effects]
The reactor 1 described above can form the gap members 31g between the core pieces 31m, ... 32m, 32m when the resin mold portion 6 is molded, and covers the outer periphery of the coil 2 and the outer periphery of the magnetic core 3 with resin. The coil 2 and the magnetic core 3 can be integrated. Therefore, for example, it is possible to simplify the work of fixing the core piece and the gap material in advance with an adhesive or the like, and individually molding the core piece and the coil with a resin. Excellent. In particular, since the interposition member 5 is formed so that all of the plurality of inner core pieces 31m,... Can be integrally held, the interposition member 5 is displaced due to pressure or the like when the resin mold portion 6 is formed by injection molding. Can be suppressed.

Other Configurations The reactor 1 can include a sensor (not shown) that measures the physical quantity of the reactor 1, such as a temperature sensor, a current sensor, a voltage sensor, and a magnetic flux sensor. For example, the sensor can be arranged in a space formed between the two winding portions 2a and 2b.

<Embodiment 2>
In the second embodiment, as shown in FIG. 4, a description will be given of an embodiment in which the intervening member 5 is formed with a larger number of grooves 53 d as the flow path 53 and the through holes 53 h divided into smaller portions. The groove 53d includes a horizontal groove 53dx and a vertical groove 53dy. The lateral groove portion 53dx is formed on both the outer peripheral surface and the inner peripheral surface of the storage portion 51. Further, the lateral groove portion 53dx is also formed on the inner peripheral surface of the annular portion 51c. The lateral groove portion 53dx formed on the outer peripheral surface of the annular portion 51c and the lateral groove portion 53dx formed on the inner peripheral surface of the annular portion 51c are provided at positions that do not overlap when viewed from the inside and outside in a plan view. By doing so, it is possible to more efficiently flow the unsolidified constituent resin of the resin mold portion up to between each of the core pieces 31m, ... 32m while ensuring the strength of the annular portion 51c. The longitudinal groove portion 53dy is formed on the inner peripheral surface of the storage portion 51 from the insertion hole 51a of the storage portion 51 downward. The through hole 53h is formed by being divided smaller than the through hole formed in the interposed member of the first embodiment. Since the through-hole 53h is divided into smaller portions, the interposition member 5 and the resin mold portion are intricately entangled, so that the bonding strength between the interposition member 5 and the resin mold portion can be further improved. Since the flow path 53 as described above is formed in the storage portion 51, the resin can easily flow in between the core pieces along the flow path 53.

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

DESCRIPTION OF SYMBOLS 1 Reactor 10 Combination 2 Coil 2a, 2b Winding part 2r Connection part 2w Winding 3 Magnetic core 31m Inner core piece 31g Gap material 32m Outer core piece 321 Outer core base part 322 Protrusion part 5 Interposition member 51 Storage part 51a, 51b Insertion Hole 51c Annular part 52 Guide part 53 Flow path 53d Groove part 53dx Horizontal groove part 53dy Vertical groove part 53h Through hole 6 Resin mold part

Claims (6)

1. A coil having a winding part;
   A magnetic core comprising a plurality of core pieces and a gap material interposed between each core piece, and having a portion disposed in the winding portion;
   An interposition member interposed between an inner surface of the winding part and the magnetic core, and holding the plurality of core pieces in a predetermined position;
   A resin mold part for integrating the coil and the magnetic core;
   The interposition member is
   Securing a space between the plurality of core pieces and positioning each core piece;
   When forming the resin mold part, comprising a flow path for flowing the unsolidified constituent resin of the resin mold part to between the plurality of core pieces,
   The gap material is a reactor formed by a constituent resin of the resin mold part.
2. The said flow path is provided with the groove part formed toward the inward from the edge part along the axial direction of the said winding part in the said interposed member in at least one of the internal peripheral surface or the outer peripheral surface of the said intermediate member. 1. The reactor according to 1.
3. The reactor according to claim 1 or 2, wherein the flow path includes a through hole penetrating from an outer surface to an inner surface of the interposition member.
4. The interposition member includes an insertion hole for inserting a plurality of inner core pieces arranged in the winding portion from the direction orthogonal to the axial direction of the winding portion among the plurality of core pieces,
   The reactor according to any one of claims 1 to 3, wherein the flow path is provided on a surface different from a surface on which the insertion hole is provided.
5. The coil includes a pair of winding portions arranged side by side,
   The interposition member integrally holds all of the plurality of inner core pieces arranged in the winding part among the plurality of core pieces for each of the pair of winding parts. The reactor of any one of Claims.
6. The coil includes a pair of winding portions arranged side by side,
   The magnetic core has a U-shape in which an outer core base disposed outside the winding part and a pair of projecting parts protruding from the outer core base and disposed in the winding part are integrally formed. With an outer core piece
   The reactor according to any one of claims 1 to 5, wherein the protruding portion of the outer core piece is inserted from an end portion of the interposed member along the axial direction of the winding portion.

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