WO2016143730A1 - Reactor - Google Patents

Abstract

Provided is a reactor which has excellent productivity and in which core pieces can easily be held at a prescribed position. 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 in the winding portion; a cylindrical interposed member that is interposed between the inner surface of the winding portion and the magnetic core and sandwiches the core pieces in a prescribed position; and a resin mold portion that unifies the coil and the magnetic core. The interposed member is composed of a pair of divided interposed members of which the peripheral direction is fragmented and which sandwich the core pieces, and is provided with a guide portion that ensures a space between the core pieces and performs positioning of the core pieces.

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, since the cylindrical portion formed on the interposed member is formed so as to cover the entire length in the insertion direction of the core piece, the core piece is inserted so as to drop from the opening of the cylindrical portion to the bottom. As a result, the core piece may be damaged during insertion. In order to insert the core piece into the cylindrical portion without damaging it, it is preferable to place the core piece in the cylindrical portion while gripping the core piece, but in this case, the workability is inferior.

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 in which core pieces can be easily held at predetermined positions and excellent in productivity.

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, a cylindrical interposition member interposed between the inner surface of the winding portion and the magnetic core, and sandwiching the plurality of core pieces at a predetermined position; and a resin for integrating the coil and the magnetic core A mold part. The interposition member is constituted by a pair of divided interposition members that are divided in the circumferential direction and sandwich the plurality of core pieces, and each core piece is positioned by securing a space between the plurality of core pieces. A guide part is provided.

The reactor is easy to hold the core pieces in place and has excellent 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 a longitudinal cross-sectional 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. FIG. 4 is a (IV)-(IV) cross-sectional view of the reactor of FIG. 1. 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 having a cylindrical shape, a cylindrical interposition member interposed between an inner surface of the winding portion and the magnetic core, and sandwiching the plurality of core pieces at predetermined positions, and the coil and the magnetic core. And a resin mold part to be converted. The interposition member is constituted by a pair of divided interposition members that are divided in the circumferential direction and sandwich the plurality of core pieces, and each core piece is positioned by securing a space between the plurality of core pieces. A guide part is provided.

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. Since the interposition member is composed of a pair of split interposition members that are divided in the circumferential direction and sandwich the plural core pieces, the plural interposition members are placed on one split interposition member, and the other split interposition member is Since the plurality of core pieces can be sandwiched simply by covering, it is easy to hold the core pieces at predetermined positions. Moreover, in the production of the assembly in the manufacturing process of the reactor, the plurality of core pieces sandwiched between the pair of split interposed members can be handled in a state in which the position of each core piece is maintained, so that the workability is excellent.

(2) As an example of the reactor described above, the interposition member includes a flow path that allows unsolidified constituent resin of the resin mold portion to flow between the plurality of core pieces when the resin mold portion is molded. The gap material may be formed of a resin component of the resin mold part.

When a mold in which a combination of a coil, a magnetic core, and an interposition member is placed is filled with an unsolidified constituent resin of the resin mold portion, the unsolidified constituent resin flows between a plurality of core pieces. A gap material having a width corresponding to the interval between them 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. .

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

(4) As an example of the reactor including the flow path, a form in which the flow path includes a through-hole penetrating from the outer surface to the inner surface of the interposition member can be given.

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.

(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, a form in which the pair of divided interposing members includes fitting portions that are fitted to each other can be given.

According to the above configuration, by fitting the pair of split interposition members with the fitting portion, both can be securely fixed. Therefore, it is possible to reliably 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. Moreover, it is easy to handle as an integrated object by fitting a pair of division | segmentation interposition members, and is further excellent in the workability | operativity of a reactor.

(7) 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. Resin core for integrating the coil 2 and the magnetic core 3 with the magnetic core 3 having a portion to be formed, the cylindrical interposition member 5 interposed between the inner surfaces of the winding portions 2a and 2b and the magnetic core 3 Part 6. 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 interposed member 5 includes a pair of divided interposed members 5A and 5B divided in the circumferential direction, and the winding portion of the magnetic core 3 is formed by the pair of divided interposed members 5A and 5B. One of the features is that a portion of the core disposed in 2a and 2b is sandwiched. Further, the interposed member 5 includes a guide portion 52 that secures a space between the plurality of core pieces 31m, ..., 32m, 32m and positions the core pieces 31m, ..., 32m, 32m. I will. Furthermore, the reactor 1 according to the first embodiment is characterized in that it includes a flow path 53 that allows the unsolidified resin of the resin mold portion 6 to flow into the spaces between the core pieces 31m, ..., 32m, 32m. 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. 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 formed. 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. Hereinafter, each configuration of the interposition member 5 will be described in detail mainly with reference to FIGS. In addition, since a pair of interposition member 5 and 5 is the same shape, below, the one interposition member 5 arrange | positioned with respect to one winding part of winding part 2a, 2b is demonstrated.

The interposition member 5 has a cylindrical shape and is constituted by a pair of divided interposition members 5A and 5B that are divided in the circumferential direction and sandwich a plurality of core pieces. In other words, the interposition member 5 is composed of a pair of divided interposition members 5A and 5B that are divided in the radiation (outer periphery) direction around the axes of the winding portions 2a and 2b. Here, as shown in FIG. 4, the split interposing members 5A and 5B are straight lines P− parallel to the upper and lower surfaces of the winding portion 2a (2b) with reference to the axis C of the winding portion 2a (2b). It is divided by P (except for the fitting portion 54). That is, the divided interposing members 5A and 5B are divided by the straight line PP so as to have a divided surface along the axial direction of the winding portion 2a (2b). The straight line PP may be parallel to the left and right surfaces of the winding portion 2a (2b), or may be a straight line such as a diagonal line of the winding portion 2a (2b). The interposition member 5 includes a cylindrical storage portion 51 that sandwiches and stores a portion of the core disposed in the winding portions 2a and 2b of the magnetic core 3 when the pair of split interposition members 5A and 5B are assembled. , 32 m, 32 m, 32 m, 32 m, 32 m, 32 m, 32 m, 32 m And a flow path 53 to be introduced.

.. Storage part The storage part 51 is cylindrical when the pair of split interposed members 5A and 5B are assembled, and is a member capable of storing all of the inner core pieces 31m, ... and the protruding part 322 of the outer core piece 32m. is there. A pair of division | segmentation interposition members 5A and 5B are each comprised by the cross-sectional U-shaped body, and become the cylindrical accommodating part 51 by abutting the opening part of a U-shaped body. The pair of split interposed members 5A and 5B are members having the same shape as shown in FIG. 3, and if the split interposed member 5A is rotated by 180 ° with respect to the split surface, the split interposed member 5B is formed.

The storage portions 51 of the divided interposing members 5A and 5B include end strips at both ends, two] strips provided at equal intervals between the end strips, and end portions at both ends on each side surface. Two linear pieces connecting the strips, and one linear piece connecting the end strips at both ends and the two] strips on the bottom surface (upper surface). Each of the end strips has a U-shaped part and a part formed integrally with the U-shaped part and having a leg shorter than the U-shaped part. The length of the leg of this] -shaped part is the same as the length of the leg of the above-mentioned] -shaped strip. The two linear pieces on each side surface are an outer straight piece connecting the U-shaped portions of the end strips, an inner straight piece connecting the] -shaped portion of the end strips and the two] strips. It is. A rectangular piece 51r (see FIG. 3) that connects the two linear pieces is provided at a substantially central portion of the outer straight piece and the inner straight piece. The U-shaped portion of the end strip is a portion where the protruding portion 322 of the outer core piece 32m is disposed. ] Strips are provided corresponding to the number of inner core pieces 31m,. In this example, two] -shaped strips are provided so that the three inner core pieces 31m,... Are arranged between the end strips. The outer straight piece and the inner straight piece arranged on each side surface are provided corresponding to the flow path 53 described later. The linear pieces arranged on the bottom surface (upper surface) are arranged so that the inner core pieces 31m,... And the protruding portions 322 of the outer core pieces 32m housed in the housing portion 51 are not dropped or displaced. Provided. A fitting portion 54 described later is formed on the rectangular piece 51r.

The inner surfaces of the storage portions 51 of the divided interposing members 5A and 5B have a shape that matches the shape of each core piece, and the corners of the end strips and the strip-shaped strips are substantially the outer peripheral surfaces of the core pieces. It is rounded along the corner. That is, the accommodating part 51 of the interposing member 5 formed by assembling the divided interposing members 5A and 5B has a shape along the shape of each inner core piece, as shown in the right view of FIG. It becomes a rectangular tube shape with rounded corners.

Each core piece is housed in the interposition member 5 when the pair of interposition members 5A and 5B are assembled, a plurality of inner core pieces 31m,... Are placed on one interposition member 5B (5A) and the other division is performed. The interposing member 5A (5B) is placed on the plurality of inner core pieces 31m, and the plurality of inner core pieces 31m are held between the pair of divided interposing members 5A and 5B. When the pair of split interposing members 5A and 5B are assembled, a cylindrical storage portion 51 is formed, and insertion holes are formed at both ends (see the right diagram in FIG. 3). The protruding portion 322 of the outer core piece 32m can be inserted and stored through this insertion hole.

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 the interposition member 5 can be inserted and arranged in the winding portion while being sandwiched between the members 5A and 5B.

The pair of split interposed members 5A and 5B includes a fitting portion 54 that fits each other. By fitting the pair of split interposing members 5A and 5B with the fitting portion 54, the split interposing members 5A and 5B can be reliably fixed to each other, and when filling the unsolidified constituent resin of the resin mold portion 6 described later, It is possible to reliably prevent misalignment between the core pieces and misalignment between the divided interposing members 5A and 5B. Moreover, it is easy to handle as a single object by fitting the pair of split interposed members 5A and 5B, and the workability of the reactor 1 is further improved.

..Fitting part The fitting part 54 is provided on an extension part 54e formed by a rectangular piece 51r extending outward from the opening side of the U-shaped body on one side surface of the split interposing members 5A and 5B, and the extension part 54e. And a fitting protrusion 54b provided on the rectangular piece 51r on the other side surface of the divided interposing members 5A and 5B. The extension portion 54e is a frame-like piece that is substantially the same size as the rectangular piece 51r, and when the pair of split interposition members 5A and 5B are assembled, the extension portion 54e of one split interposition member 5A (5B) , And overlaps the rectangular piece 51r of the other divided interposing member 5B (5A). The extension portion 54e and the rectangular piece 51r are formed so that the total thickness of the two portions 54e and 51r when the two portions 54e and 51r overlap with each other is the thickness between the inner surface and the outer surface of the storage portion 51. Here, the fitting hole 54a is formed over the extending direction of the extending portion 54e, but may be formed only at the tip portion of the extending portion 54e in the extending direction. The fitting protrusion 54b protrudes from the rectangular piece 51r and is formed in a wedge shape having an inclined surface that tapers in the protruding direction and the fitting hole 54a direction. The protrusion length of the fitting protrusion 54b is substantially the same as the thickness of the extension portion 54e. The fitting protrusion 54b is in contact with the periphery of the fitting hole 54a provided in the extension portion 54e (the periphery of the tip portion in the extension direction of the extension portion 54e) when the pair of split interposed members 5A and 5B are assembled. Is provided.

In this example, as a fixing means for the pair of split interposed members 5A and 5B, the pair of split interposed members 5A and 5B has been described as having a fitting portion 54 that fits each other. The divided interposition members 5A and 5B can be fixed to each other, or the divided interposition members 5A and 5B can be fixed with an adhesive.

.. 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 an L-shaped protrusion formed on the] -shaped portion of the end strip and the corners of each] -shaped strip. Therefore, when the plurality of inner core pieces 31m,... Are stored in the storage portion 51, the guide portions 52 are interposed at the four corners of the gap between the inner core pieces 31m,.

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 sandwiching the inner core pieces 31m between the pair of divided interposing members 5A, 5B, and the gap material 31g is provided between the inner core pieces 31m,. A gap corresponding to the thickness of the film can be formed.

Moreover, the end surface of the protrusion part 322 is inserted in the guide part 52 in an end part only by inserting the protrusion part 322 of the outer core piece 32m from the insertion hole formed in both ends by assembling a pair of division | segmentation interposition members 5A and 5B. Can be positioned, so that the outer core piece 32m can be positioned. Therefore, each of the core pieces 31m, ..., 32m, 32m can be positioned by the guide portions 52 of the pair of divided interposing members 5A, 5B.

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. Therefore, the interval between the inner core pieces 31m,... Can be secured, 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. Furthermore, it is preferable to adjust the protrusion amount of the guide portion 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 portion 52 is an L-shaped ridge formed at the corner of each] -shaped strip, but if the core pieces 31m, ..., 32m can be positioned by the guide portion 52, The shape of the guide part 52 is not particularly limited. For example, the guide part 52 may be a U-shaped ridge along the circumferential direction of each] -shaped body.

.. 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 in 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 portion 53d includes a lateral groove portion 53dx formed from both edge portions of the storage portion 51 inward in the axial direction of the winding portion, and a vertical groove portion formed along the circumferential direction of the storage portion 51. 53dy. 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,. Moreover, by providing the through-hole 53h formed so that the gap between the core pieces 31m,... 32m is exposed, the unsolidified constituent resin is more likely to flow into between the core pieces 31m,. 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 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 Drawing 2, a plurality of inner core pieces 31m and ... are pinched by a pair of division intervention members 5A and 5B. At that time, the fitting portions 54 provided on the pair of split interposed members 5A and 5B are fitted to each other. Specifically, along with the proximity of both split interposed members 5A and 5B, the extension 54e of the other split interposed member 5A (5B) is formed on the inclined surface of the fitting projection 54b of one split interposed member 5B (5A). By sliding, the extended portion 54e is elastically deformed and spreads outside the frame-shaped piece. And the fitting protrusion 54b is engage | inserted by the fitting hole 54a formed in this extension part 54e, The extension part 54e which was elastically deformed is returned to the state before a deformation | transformation. Thereby, the fitting protrusion 54b is latched in the fitting hole 54a of the extension portion 54e, and the divided interposing members 5A and 5B are fixed to each other. By doing so, each inner core piece 31m will be stored in the cylindrical storage portion 51. At this time, a gap corresponding to the thickness of the gap material 31g is formed between the inner core pieces 31m,... By the pair of divided interposing members 5A, 5B, and positioning of the inner core pieces 31m,. A 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, 32m are inserted into the projecting portions 322, 322 through insertion holes formed at both ends of the cylindrical storage portion 51. 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 composed of a pair of split interposition members 5A, 5B, the plurality of inner core pieces 31m,... Can be easily accommodated by being sandwiched between the pair of split interposition members 5A, 5B. Since the plurality of inner core pieces 31m,... Are sandwiched and housed between the pair of split interposed members 5A, 5B, the inner core pieces 31m,. It is possible to suppress a positional shift due to a pressure or the like when molding the material by injection molding.

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 illustrated in FIG. 5, a description will be given of a mode in which the interposition member 5 is formed with a larger number of grooves 53 d and a through hole 53 h that is divided into smaller portions as the flow path 53.

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, a large number of the lateral groove portions 53dx are formed on the inner peripheral surface of the U-shaped strip at both ends of the storage portion 51. The lateral groove portion 53dx formed on the outer peripheral surface of the U-shaped strip and the lateral groove portion 53dx formed on the inner peripheral surface of the U-shaped strip 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 between the core pieces while ensuring the strength of the storage portion 51. The longitudinal groove portion 53 dy is formed along the circumferential direction of the storage portion 51.

The through hole 53h is formed to be smaller than the through hole formed in the interposition 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. A through hole 53h is also formed in the rectangular piece 51r on which the fitting protrusion 54b is formed. Even if the rectangular piece 51r and the extension portion 54e are overlapped, the fitting hole 54a formed in the extension portion 54e is widely formed in the extending direction of the extension portion 54e, so that the rectangular piece 51r is formed. The through-hole 53h is not blocked by the extension 54e. 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 Combined body 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 5A, 5B Splitting intermediate member 51 Storage part 51r Rectangular piece 52 Guide part 53 Flow path 53d Groove part 53dx Horizontal groove part 53dy Vertical groove part 53h Through hole 54 Fitting part 54e Extension part 54a Fitting hole 54b Fitting protrusion 6 Resin mold part

Claims (7)

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;
   A cylindrical interposition member interposed between an inner surface of the winding portion and the magnetic core, and sandwiching the plurality of core pieces at a predetermined position;
   A resin mold part for integrating the coil and the magnetic core;
   The interposition member is
   The circumferential direction is divided and is composed of a pair of divided interposing members that sandwich the plurality of core pieces,
   A reactor including a guide portion that secures a space between the plurality of core pieces and positions each core piece.
2. The interposition member includes a flow path that allows unsolidified constituent resin of the resin mold portion to flow between the plurality of core pieces when the resin mold portion is molded.
   The reactor according to claim 1, wherein the gap material is formed of a constituent resin of the resin mold portion.
3. 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. 2. The reactor according to 2.
4. The reactor according to claim 2 or 3, wherein the flow path includes a through-hole penetrating from an outer surface to an inner surface of the interposition member.
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 reactor according to any one of claims 1 to 5, wherein the pair of divided interposing members includes fitting portions that fit into each other.
7. 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 6, 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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