WO2017014160A1 - Reactor - Google Patents

Abstract

A reactor provided with an assembly including a coil and a magnetic core which is disposed on the inside and outside of the coil and which forms a closed magnetic path. The magnetic core is disposed on the outside of the coil and provided with an outer core portion made of a material including resin. The reactor is provided with a fixing member including a plurality of tubular portions which are integrated with the resin and through which bolts for fixing the assembly to an object to be installed are passed, and a block-shaped link portion linking the plurality of tubular portions.

Description

Reactor

The present invention relates to a reactor.
This application claims priority based on Japanese Patent Application No. 2015-146244, filed July 23, 2015, and incorporates all the contents described in the aforementioned Japanese application.

Patent Document 1 discloses a reactor including a coil formed by winding a winding, and a magnetic core that is disposed inside and outside the coil and forms a closed magnetic circuit with the excitation of the coil. The connection core part (outer core part) arrange | positioned outside a coil among this magnetic core is comprised from the mixture of a magnetic material and resin, and is provided with an attaching part as a part of this outer core part. The mounting portion has a bolt insertion hole for fixing to the installation target.

JP 2011-129593 A

A reactor of the present disclosure is a reactor including a combination including a coil and a magnetic core that is disposed inside and outside the coil to form a closed magnetic path,
The magnetic core is disposed outside the coil, and includes an outer core portion made of a material containing resin,
A fixing member that is integrated with the resin and includes a plurality of cylindrical portions through which bolts that fix the combination to an installation target pass, and a block-shaped connecting portion that connects the plurality of cylindrical portions. Prepare.

1 is a schematic perspective view of a reactor according to a first embodiment. 1 is a schematic exploded perspective view of a reactor according to a first embodiment. FIG. 3 is a (III)-(III) cross-sectional view of the reactor of FIG. FIG. 4 is a (IV)-(IV) cross-sectional view of the reactor of FIG. It is sectional drawing of the reactor which concerns on Embodiment 2. FIG. It is sectional drawing of the reactor which concerns on Embodiment 3. FIG.

[Problems to be solved by the present disclosure]
In the reactor of patent document 1, since the attachment part is comprised with the material (material which comprises an outer core part) containing resin, it exists in the tendency which is inferior in terms of intensity | strength. Therefore, when a bolt is inserted into the insertion hole of the mounting portion and tightened, stress accompanying the bolt tightening force may be excessively generated in the resin portion.

Generally, each bolt in the mounting part is tightened one by one. For example, as in Patent Document 1, when there are a plurality of insertion holes close to one mounting portion, if a bolt is inserted into one insertion hole and fixed to an installation target, the bolt is tightened to the other insertion hole. Before, it is easy to produce a level | step difference between other insertion holes on the basis of installation object. When this level difference occurs, bending stress is generated in the resin portion existing around the insertion hole. Depending on the magnitude of this bending stress, excessive stress may be applied to the vicinity of the opening of the insertion hole where the bolt is tightened or the resin portion between the two insertion holes, causing damage such as cracking in the outer core portion. .

Therefore, it is an object of the present invention to provide a reactor that is less likely to cause damage to the magnetic core and is excellent in productivity when the reactor is attached to the installation target.

[Effects of the present disclosure]
The reactor according to the present disclosure is excellent in productivity because the magnetic core is hardly damaged when the reactor is attached to the installation target.

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

(1) A reactor according to an embodiment of the present invention is a reactor including a combination of a coil and a magnetic core that is disposed inside and outside the coil to form a closed magnetic path, and the magnetic core is A plurality of cylindrical portions that are arranged outside the coil and include an outer core portion made of a resin-containing material, and are integrated with the resin, and through which bolts that fix the assembly to the installation target pass. And a fixing member having a block-like connecting portion that connects the plurality of cylindrical portions.

The “material including the resin” constituting the outer core portion only needs to include a magnetic portion and a resin portion, and the existence form of the magnetic portion and the resin portion is not limited. For example, the outer core portion may include a compact including a soft magnetic powder (magnetic part) and a resin coating (resin part) formed on the surface of the compact (this form). Is called mold core type). In the outer core portion of the mold core type, the magnetic portion and the resin portion are independent. In addition, the outer core part may be formed of a composite material including soft magnetic powder (magnetic part) and resin (resin part) (this form is referred to as a resin core type). In the outer core portion of the resin core type, the magnetic portion and the resin portion are mixed. Examples of the outer core part include a form in which a resin coating part (resin part) is provided on the surface of a resin core (mixed magnetic part and resin part) made of a composite material (this form is referred to as a composite core type).

The “resin” in which the fixing member is integrated may be a resin portion alone or a resin portion of a composite material including a resin portion and a magnetic portion in the “resin-containing material”. For example, when the outer core portion is a mold core type, the fixing member is integrated with the resin coating portion (only the resin portion). In addition, when the outer core portion is a resin core type, the fixing member is integrated with the resin portion of the composite material. When the outer core part is a resin core type, the resin part also integrates the magnetic part. When the outer core portion is a composite core type, the fixing member is integrated with the resin coating portion (only the resin portion). Details of each core type will be described later.

The reactor according to the present embodiment is a bending member that is generated around a cylindrical portion by fastening the bolts one by one in a fixing member having a plurality of cylindrical portions by connecting the plurality of cylindrical portions with a connecting portion. The stress can be absorbed by the connecting portion, and the occurrence of damage such as cracking in the outer core portion can be suppressed. Therefore, said reactor can fix an outer core part to installation object with a volt | bolt, without damaging an outer core part (magnetic core). By providing the connecting portion, the reactor described above can suppress the occurrence of damage such as cracking in the outer core portion without carefully considering the bending stress accompanying tightening of the bolt. Therefore, the attachment property to the installation object of the reactor can be improved, and the productivity of the reactor is excellent.

Conventionally, when a reactor is attached to an installation target, the reason why a step is generated between the cylindrical portions with respect to the installation target is that the reactor mounting portion or the installation target has a dimensional error. Although the above steps can be reduced by carefully managing the dimensions of the reactor mounting portion and the installation target, the productivity is inferior. The reactor of this embodiment can absorb the bending stress generated around the cylindrical portion at the connecting portion even if the step is generated, so the attachment density of the reactor and the dimensional management cotton density of the installation target are alleviated. It can be used and has excellent productivity. In addition, it is possible to reduce the dimensional tolerance of the installation part of the reactor and the installation target, and the productivity of the reactor is excellent.

(2) As an example of the reactor described above, a form in which the outer core portion includes a protruding molded portion that encloses a part of the fixing member may be mentioned.

The fixing member can be reliably integrated with the outer core portion by providing the outer core portion with the protruding molded portion. In addition, for example, the projecting molded part can be provided so as to project from the main body part serving as the magnetic path of the outer core part. In this case, the fixing member is easily integrated with the main body part by the projecting molded part, and can be easily attached to the installation target. .

(3) As an example of the reactor described above, a configuration in which the fixing member includes a pressure-supporting portion that extends in an outer peripheral direction from each end of the cylindrical portion and receives a tightening force of the bolt.

When the bolt is inserted into the cylindrical part and tightened, the bolt tightening force acts on the bearing part. Therefore, the bolt tightening force received by the outer core portion is reduced as compared with the case where there is no supporting pressure portion. Therefore, it can suppress that damage, such as a crack, arises in the outer core part in the opening vicinity of a cylindrical part.

(4) As an example of the reactor described above, a form in which the connecting portion includes a surface that is flush with the end surface of the cylindrical portion may be mentioned.

The connecting part has a surface flush with the end face of the cylindrical part, that is, the end face of the cylindrical part and the axial surface of the bolt in the connecting part are flush with each other, so that the rigidity of the end face of the cylindrical part is Can be improved. Therefore, it is possible to suppress the occurrence of a step between the cylindrical portions with respect to the installation target when the reactor is attached to the installation target.

(5) As an example of the reactor described above, the connecting portion may be embedded in the resin.

Since the connecting portion is embedded in the “resin” described above, the connecting portion is more firmly fixed by the resin. Therefore, it is easy to suppress that a connection part falls off from an outer core part.

(6) As an example of the reactor described above, the outer core portion includes a green compact including soft magnetic powder, and a resin coating formed on the surface of the green compact, and the fixing member is And a form integrated with the resin coating portion.

Since the fixing member can be easily integrated with the resin coating portion made of resin, it is possible to suppress a decrease in the productivity of the reactor due to the formation of the fixing member.

(7) As an example of the reactor described above, the outer core portion may be composed of a composite material including soft magnetic powder and resin, and the fixing member may be integrated with the resin of the composite material. .

Since the fixing member can be easily integrated with a composite resin including soft magnetic powder and resin, it is possible to suppress a reduction in reactor productivity due to the formation of the fixing member.

(8) As an example of the above-described reactor, the coil includes a pair of winding portions arranged side by side, and the magnetic core is disposed outside the coil and a pair of inner core portions disposed inside the coil. An outer core portion to be disposed, and the plurality of cylindrical portions may be present between the extended surfaces of the outer surfaces of the pair of inner core portions.

Even if the cylindrical portion of one fixing member is close enough to exist between the extended surfaces of the pair of inner core portions, the bending stress generated around the cylindrical portion is connected if the reactor is the above-described reactor. It can absorb by a part and it can control that damage, such as a crack, arises in an outside core part.

(9) As an example of the reactor described above, the fixing member may be made of metal.

Since the fixing member is made of metal, it is easy to form a connecting portion having such rigidity that the outer core portion does not crack due to bending stress.

[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 it is intended that all the changes within the meaning and range equivalent to a claim are included. The same code | symbol in a figure shows the same name thing.

<Embodiment 1>
The reactor 1α according to the first embodiment will be described with reference to FIGS.

[Reactor]
Overall Configuration The reactor 1α according to the first embodiment is disposed inside and outside of the winding portions 2a and 2b and a coil 2 having winding portions 2a and 2b formed by spirally winding the windings to form a closed magnetic circuit. A combination 10 having a magnetic core 3 is provided. Reactor 1α (combined body 10) is installed and used on installation object 9 (FIG. 3) such as a cooling base. Therefore, the reactor 1α includes a fixing member 4 for fixing the combined body 10 to the installation target 9. The fixing member 4 is integrated with a constituent material (resin) constituting the outer core portion 32 disposed outside the coil 2 in the magnetic core 3. In the reactor 1α of the first embodiment, the fixing member 4 includes a plurality of cylindrical portions 41a and 41b through which the bolts 7 (FIG. 3) are inserted, and a connecting portion 42 that connects the plurality of cylindrical portions 41a and 41b. One of the features is the provision. Hereinafter, each configuration will be described in detail. In the following description, when the reactor 1α is installed on the installation target 9, the installation target 9 side of the reactor 1α is described as the lower side, and the opposite side is described as the upper side.

As shown in FIGS. 1 and 2, the coil 2 includes a pair of cylindrical winding portions 2a and 2b formed by spirally winding a single continuous winding, A coil connecting portion 2r for connecting the winding portions 2a and 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 coil 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.

In this example, each winding part 2a, 2b 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 this example, the coil 2 is formed by edgewise winding a coated rectangular wire made of a copper rectangular wire and an insulating coating made of enamel (typically polyamideimide).

-Magnetic core The magnetic core 3 is comprised combining a pair of division | segmentation core 3A, 3B, as shown in FIG. The configuration of the split core 3A and the configuration of the split core 3B are the same. If the split core 3A is rotated 180 ° in the horizontal direction, the split core 3B is obtained. Note that the split cores 3A and 3B do not necessarily have the same shape.

As shown in FIGS. 2 and 4, the split core 3 </ b> A (3 </ b> B) integrates a plurality of columnar inner core pieces 31 m,..., A U-shaped outer core piece 32 m, and each core piece 31 m,. And a resin coating portion 30 to be provided. The inner core piece 31m is a magnetic piece that is entirely disposed in the winding portions 2a and 2b, and the outer core piece 32m is a magnetic piece having a portion that is disposed outside the winding portions 2a and 2b. It is. The outer core piece 32m may have a portion partially disposed in the winding portions 2a and 2b. In this example, the outer core piece 32m is disposed outside the winding portions 2a and 2b. It has both a part and the part arrange | positioned in winding part 2a, 2b.

It is preferable that the inner core piece 31m has a shape that matches the shape of the winding portions 2a and 2b. Here, 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.

The outer core piece 32m is substantially U-shaped when viewed from above in FIG. The outer core piece 32m includes a columnar portion whose upper surface and lower surface are substantially dome-shaped, and a pair of protruding portions protruding from the columnar portion. The columnar part and the pair of projecting parts are integrally formed. The columnar portion is disposed outside the winding portions 2a and 2b and is disposed so as to straddle between the winding portions 2a and 2b. A pair of protrusion part has a part arrange | positioned in winding part 2a, 2b. The end surfaces of the pair of protruding portions have substantially the same shape and size as the end surface of the inner core piece 31m, and the size and the protruding length are appropriately selected so as to have a predetermined magnetic path cross-sectional area corresponding to the coil 2 it can. The pair of projecting portions preferably have a shape that matches the shape of the winding portions 2a and 2b. Here, the corner portions are substantially rounded along the corner portions of the inner peripheral surfaces of the winding portions 2a and 2b. It has been.

The inner core piece 31m and the outer core piece 32m are compacted bodies containing soft magnetic powder. 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 pressure-molded, it is obtained by performing a heat treatment for the purpose of removing distortions 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.

The resin coating 30 has a role of integrating the inner core piece 31m and the outer core piece 32m and protecting the core pieces 31m and 32m from the external environment. The resin coating portion 30 is also arranged between the inner core pieces 31m and 31m and between the inner core piece 31m and the outer core piece 32m, and a portion arranged between the core pieces 31m and 32m is a gap. Functions as a material. Moreover, the resin coating | coated part 30 equips the part of the outer side (left-right direction of FIG. 4) in the columnar part of the outer core piece 32m with a hook-shaped part. The bowl-shaped portion formed by the resin coating portion 30 is a protruding molded portion 32B in the outer core portion 32 described later. In addition, the resin coating portion 30 includes a partition portion 3d that protrudes at a position between the pair of protruding portions so as to ensure insulation between the winding portions 2a and 2b.

Examples of the resin constituting the resin coating portion 30 include thermosetting resins such as epoxy resins, phenol resins, silicone resins, and urethane resins, and polyamide (PA) resins such as polyphenylene sulfide (PPS) resins, nylon 6, and nylon 66. A thermoplastic resin such as polyimide resin or fluororesin, a room temperature curable resin, or a low temperature curable resin can be used. A ceramic filler such as alumina or silica may be included in these resins to improve the heat dissipation of the resin coating portion 30.

When the pair of split cores 3A and 3B are combined, the outer core pieces 32m and 32m are arranged so that the U-shaped openings face each other, and the inner core pieces 31m,... Are arranged side by side between the outer core pieces 32m and 32m (in parallel). ). 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. The part arrange | positioned in winding part 2a, 2b among the magnetic cores 3 is the inner core part 31, and while being arrange | positioned outside winding part 2a, 2b, and the axial direction of winding part 2a, 2b, A portion arranged in the orthogonal direction is the outer core portion 32.

The outer core portion 32 includes a main body portion 32A serving as a magnetic path, and a projecting molding portion 32B provided integrally with the resin coating portion 30 on the outer side of the main body portion 32A. The main body portion 32A is a portion that becomes a main magnetic path formed in the magnetic core 3 when the coil 2 is excited, and the above-described outer core piece 32m and the resin coating portion 30 disposed on the outer periphery of the outer core piece 32m. And comprising. The protruding molded portion 32B includes a portion formed by the resin coating portion 30, and does not include a core piece.

The protruding molded portion 32B has a size (such as a protruding length and thickness) that can maintain a fixed state with respect to the installation target 9 when the bolt 7 is tightened or when the reactor 1α is used. Here, the protruding molded portion 32B is molded so as to project in the axial direction of the winding portions 2a and 2b from a position near the middle in the height direction (vertical direction in FIG. 1) of the main body portion 32A. The protruding molded part 32B includes a part of the fixing member 4 described later.

In this example, the protruding molded part 32B is provided at a position near the middle in the height direction of the main body part 32A, but may be provided at an upper or lower position in the height direction of the main body part 32A.

In this example, the split core 3A (3B) is formed to include a long protruding portion 3L and a short protruding portion 3S. The long projecting portion 3L includes a thick portion 3a and a narrow portion 3b having different radial dimensions. The narrow portion 3b is formed thinner than the thick portion 3a, and the inner core piece 31m is exposed from the end surface of the narrow portion 3b (that is, the end surface of the long protruding portion 3L). The short protruding portion 3 </ b> S includes a cylindrical storage portion 3 c formed by the resin coating portion 30. The inner peripheral shape of the storage portion 3c substantially matches the outer peripheral shape of the narrow portion 3b of the long projecting portion 3L, and the narrow portion 3b of one split core 3A (3B) is replaced with the other split core 3B. (3A) can be stored in the storage portion 3c (see FIG. 4). The split cores 3A and 3B can be mechanically joined to each other by fitting the narrow portion 3b and the storage portion 3c.

-Fixed member The fixed member 4 is integrated with the protrusion molding part 32B of the outer core part 32 mentioned above. That is, the fixing member 4 is located away from the main magnetic path formed in the magnetic core 3 when the coil 2 is excited. The fixing member 4 includes a plurality (two in this case) of cylindrical portions 41a and 41b through which the bolts 7 pass, a block-shaped connecting portion 42 that connects the cylindrical portions 41a and 41b, and the cylindrical portions 41a and 41b. And a support pressure portion 43 extending in the outer peripheral direction from the end portion. The fixing member 4 is an integral body in which the cylindrical portions 41a and 41b, the connecting portion 42, and the support pressure portion 43 are integrally provided.

In this example, the installation target 9 includes a mounting surface 91 on which the reactor 1α (union 10) is mounted and a columnar base portion 92 extending upward from the mounting surface 91 (see FIG. 3). A mounting hole 92 h for the bolt 7 is formed in the base 92. When the bolts 7 are attached in a state where the cylindrical portions 41a and 41b of the fixing member 4 and the attachment holes 92h of the base portion 92 are combined, the reactor 1α (the combined body 10) is fixed to the installation target 9.

When the fixing member 4 is tightened by inserting the bolts 7 into the cylindrical portions 41a and 41b, various materials having rigidity that does not easily cause damage such as cracks in the protruding molded portion 32B (outer core portion 32) can be used. it can. As a constituent material of the fixing member 4, it is preferable to use a metal material such as aluminum or an alloy thereof, magnesium or an alloy thereof, copper or an alloy thereof, iron or austenitic stainless steel. In particular, a nonmagnetic material such as austenitic stainless steel is preferable. If the fixing member 4 is excellent in thermal conductivity, it can be expected that even if the outer core portion 32 generates heat during the operation of the reactor 1α, the fixing member 4 can radiate heat using the fixing member 4 as a heat dissipation path.

..Cylindrical portions The cylindrical portions 41a and 41b have both end surfaces flush with the surface of the protruding molded portion 32B. That is, the cylindrical portions 41a and 41b are provided over the entire region in the height direction (the vertical direction in FIGS. 1 and 3) of the protruding molded portion 32B. The cylindrical portions 41a and 41b have such a thickness that the protruding molded portion 32B (outer core portion 32) is not damaged such as cracking when the bolt 7 is tightened or when the reactor 1α is used. The thickness of the cylindrical portions 41a and 41b referred to here is the length from the inner peripheral surface in the direction away from the adjacent cylindrical portions 41a and 41b to the boundary surface between the protruding molded portions 32B. In this example, since the cylindrical parts 41a and 41b are connected by the connection part 42 mentioned later over the whole region, the length between cylindrical parts 41a and 41b is not included in the said thickness.

As shown in FIG. 4, the cylindrical portions 41a and 41b exist between the extended surfaces PP of the outer side surfaces of the pair of inner core portions 31 and 31 (FIG. 1). If the cylindrical portions 41a and 41b are close enough to exist between the extended surfaces PP, excessive bending stress is likely to act between the cylindrical portions 41a and 41b when the bolt 7 is tightened, so that protrusion molding is performed. The part 32B (outer core part 32) is likely to be damaged such as cracks. Since the fixing member 4 of the present embodiment includes a connecting portion 42 described later, even if the cylindrical portions 41a and 41b are close enough to exist between the extended surfaces PP, the protruding molded portion 32B (outer core) It is possible to suppress the occurrence of damage such as cracks in the portion 32).

..Connecting part The connecting part 42 is a bending stress generated around the cylindrical parts 41a and 41b when the reactor 1α (the combined body 10) is attached to the installation target 9, and is formed on the projecting molded part 32B (outer core part 32). It has rigidity that does not cause damage such as cracks. In order for the connecting portion 42 to have the above-described rigidity, a high-rigidity material is used as the constituent material of the connecting portion 42 (fixing member 4), or the contact area between the connecting portion 42 and the protruding molded portion 32B is increased. Is mentioned.

As the contact area between the connecting portion 42 and the protruding molded portion 32B increases, the amount of bending stress generated around the cylindrical portions 41a and 41b increases, so that the protruding molded portion 32B is prevented from being damaged such as cracks. Easy to do. The fixing member 4 is included in the protruding molding part 32 </ b> B and integrated with the outer core part 32. At this time, it is preferable that the fixing member 4 has a peripheral surface (a surface other than the upper and lower end surfaces in FIG. 1) included in the protruding molded portion 32B. That is, it is preferable that the connecting portion 42 has a peripheral surface (a surface other than the end surface in the height direction) in contact with the protruding molded portion 32B.

Here, the connecting portion 42 has a surface flush with the end faces of the tubular portions 41a and 41b. That is, the end surfaces of the cylindrical portions 41a and 41b and the end surface of the connecting portion 42 are flush with each other, whereby the rigidity of the end surfaces of the cylindrical portions 41a and 41b can be improved. When the rigidity of each end face of the cylindrical portions 41a and 41b is high, the installation object 9 is used as a reference before the bolt 7 of the one cylindrical portion 41a is tightened and when the bolt 7 is tightened to the other cylindrical portion 41b. It can suppress that a level | step difference arises between cylindrical part 41a, 41b as.

.. Supporting part The supporting part 43 has a size that extends outward from the outer peripheral edge of the head of the bolt 7. By doing so, the head portion of the bolt 7 is surely in contact with the bearing portion 43, so that the tightening force of the bolt 7 can be reliably received by the bearing portion 43. It is preferable that the pressure-supporting portion 43 is provided over the entire region in the height direction of the fixing member 4 (the height direction of the protruding molded portion 32B). By doing so, it is easy to absorb the tightening force of the bolt 7 by the support pressure part 43, and it is easy to suppress the occurrence of damage such as a crack in the protruding molded part 32B.

The fixing member 4 can be easily integrated with the protruding molded portion 32B by insert molding when integrally forming the protruding molded portion 32B with the resin coating portion 30 of the outer core portion 32. In addition, the fixing member 4 can be integrated with the protruding molding portion 32B by pressing the fixing member 4 into the protruding molding portion 32B after the protruding molding portion 32B is integrally formed with the resin coating portion 30 of the outer core portion 32. Can do. In the case where the fixing member 4 is press-fitted after the protrusion molding portion 32B is formed by the resin coating portion 30, a storage hole for the fixing member 4 may be formed in the protrusion molding portion 32B when the protrusion molding portion 32B is molded.

Other configuration The reactor 1α is disposed between the outer peripheral surface of the inner core portion 31 and the inner peripheral surfaces of the winding portions 2a and 2b, and adheres the inner core portion 31 and the winding portions 2a and 2b. A sheet (not shown) can be provided. Since the relative position between the coil 2 and the magnetic core 3 can be fixed by the adhesive sheet, the relative positional deviation between the coil 2 and the magnetic core 3 due to vibration during the operation of the reactor 1α is suppressed. Can do.

The adhesive sheet can be made of an insulating resin having adhesiveness, for example, a thermosetting resin such as an epoxy resin, a silicone resin, or an unsaturated polyester, or a thermoplastic resin such as a PPS resin or LCP. The thermal conductivity of the adhesive sheet may be improved by incorporating these ceramic fillers into the insulating resin. Moreover, an adhesive sheet can also be comprised with a foamed resin. In the case of an adhesive sheet made of foamed resin, an unfoamed adhesive sheet is attached to each protruding portion (inner core portion 31) of each divided core 3A, 3B, and then the protruding portion of each divided core 3A, 3B is wound. Easy to insert into the parts 2a, 2b. The coil 2 and the magnetic core 3 can be fixed if the unfoamed resin is foamed after inserting the protruding portions into the winding portions 2a and 2b.

〔effect〕
In the fixing member 4 having the plurality of cylindrical portions 41a and 41b, the reactor 1α described above is before the bolt 7 of one cylindrical portion 41a is tightened when the bolt 7 is tightened one by one. When the bolt 7 is fastened to the cylindrical portion 41b, it is possible to suppress the occurrence of damage such as cracks in the protruding molded portion 32B (outer core portion 32). Since the plurality of cylindrical portions 41 a and 41 b are connected by the connecting portion 42, the bending stress generated around the cylindrical portions 41 a and 41 b can be absorbed by the connecting portion 42 when the bolt 7 is tightened. is there. In particular, when a plurality of cylindrical portions 41a and 41b exist close to each other (for example, between the extended surfaces PP of the outer side surfaces of the pair of inner core portions 31), the periphery of the cylindrical portions 41a and 41b However, if the reactor 1α described above is used, the bending stress can be effectively absorbed by the connecting portion 42, thereby causing damage such as cracks in the protruding molded portion 32B (outer core portion 32). Can be suppressed.

The reactor 1α described above improves the rigidity of the end portions of the tubular portions 41a and 41b because the end surfaces of the tubular portions 41a and 41b and the surface of the connecting portion 42 in the height direction are flush with each other. Can do. Therefore, before the bolt 7 of one cylindrical part 41a is tightened, when the bolt 7 is tightened to the other cylindrical part 41b, a step is generated between the cylindrical parts 41a and 41b with the installation object 9 as a reference. Can be suppressed.

<Embodiment 2>
In the second embodiment, as shown in FIG. 5, a reactor 1β in which the connecting portion 42 of the fixing member 4 is embedded in the constituent resin of the protruding molded portion 32B will be described. The reactor 1β of the second embodiment is different from the first embodiment only in that the connecting portion 42 is embedded in the constituent resin, and the other configurations are the same as those of the first embodiment. The cylindrical portions 41 a and 41 b have a thickness corresponding to the size of the pressure bearing portion 43. That is, the pressure bearing portion 43 is provided over the entire region in the height direction (vertical direction in FIG. 5) of the fixing member 4, and the cylindrical portions 41 a and 41 b have a thickness portion that functions as the pressure bearing portion 43. Have both.

The connecting portion 42 is arranged inward from each surface (upper and lower surfaces in FIG. 5) of the protruding molded portion 32B in the height direction. That is, the height of the connecting portion 42 is slightly smaller than the height of the protruding molded portion 32B. Therefore, the fixing member 4 has an H-shaped cross section.

The fixing member 4 of the second embodiment is firmly fixed by the constituent resin at the connecting portion 42 portion because the connecting portion 42 is embedded in the constituent resin of the protruding molded portion 32B. Therefore, it can suppress that the fixing member 4 falls off from the protrusion molding part 32B (outer core part 32). Since the connection part 42 is small compared with the connection part of Embodiment 1, the constituent material of the fixing member 4 can be reduced and the weight reduction of the reactor 1 (beta) can be anticipated.

<Embodiment 3>
In the third embodiment, as shown in FIG. 6, a reactor 1 γ will be described in which the pressure-supporting portion 43 of the fixing member 4 is thin and includes a flat plate member 5 as a reinforcing member of the pressure-supporting portion 43. In the reactor 1γ of the third embodiment, the connecting portion 42 is embedded in the constituent resin of the protruding molded portion 32B. The reactor 1γ according to the third embodiment is different from the second embodiment in that the thickness of the pressure bearing portion 43 is thin and the flat plate member 5 is provided.

If the thickness of the support portion 43 is small, the amount of tightening force of the bolt 7 absorbed by the support portion 43 is small, and there is a possibility that damage such as cracks may occur in the protruding molded portion 32B in the vicinity of the tubular portions 41a and 41b. . Therefore, a flat plate member 5 that is fastened to the bearing portion 43 (fixing member 4) by the bolt 7 is disposed as a reinforcing member of the bearing portion 43. As the flat plate member 5, the same material as that of the fixing member 4 can be used. Since the pressure bearing part 43 is thin, the constituent material of the fixing member 4 can be reduced, and the weight reduction of the reactor 1γ can be expected.

In this example, the flat plate member 5 is formed with two through holes 5h and has a size straddling the cylindrical portions 41a and 41b. Since the flat plate member 5 has a size straddling the tubular portions 41a and 41b, the rigidity of each end face of the tubular portions 41a and 41b can be improved. When the rigidity of each end face of the cylindrical portions 41a and 41b is high, the installation object 9 is used as a reference before the bolt 7 of the one cylindrical portion 41a is tightened and when the bolt 7 is tightened to the other cylindrical portion 41b. It can suppress that a level | step difference arises between cylindrical part 41a, 41b as. The thickness of the flat plate member 5 may be a thickness that can absorb the tightening force by the bolt 7. The flat plate member 5 may be individually arranged for each bolt 7. Even if the flat plate members 5 are arranged individually, the flat plate member 5 can absorb the tightening force of the bolts 7.

When the bolt 7 is attached in a state where the through hole 5h of the flat plate member 5, the cylindrical portions 41a and 41b of the fixing member 4 and the mounting hole 92h of the base portion 92 are combined, the flat plate member 5 It is interposed between the head and the pressure bearing part 43 of the fixing member 4. Even if the fixing member 4 is not provided with the pressure bearing portion 43, the tightening force of the bolt 7 is absorbed by the flat plate member 5 by adjusting the rigidity of the flat plate member 5, and in the vicinity of the cylindrical portions 41a and 41b. It is possible to suppress the occurrence of damage such as cracks in the protruding molded part 32B. In the case where the fixing member 4 is not provided with the supporting pressure portion 43, the flat plate member 5 is interposed between the head of the bolt 7 and the resin portion of the protruding molded portion 32B and the end surfaces of the cylindrical portions 41a and 41b.

<Embodiment 4>
The reactors 1α, 1β, and 1γ of Embodiments 1 to 3 include a compacted body in which the outer core portion 32 includes soft magnetic powder, and a resin coating portion 30 that is formed on the surface of the compacted body, The form in which the fixing member 4 is integrated with the resin coating portion 30 has been described. In addition, when the outer core portion is composed of a composite material including soft magnetic powder and resin, the fixing member can be integrated with the resin of the composite material. That is, the outer core portion includes a main body portion made of the composite material, and a protruding molding portion that protrudes from the main body portion and is made of the same composite material, and the fixing member is a resin of the composite material of the protruding molding portion. And integrated. An inner core part can also be comprised with the said composite material.

As the soft magnetic powder, the same soft magnetic powder that can be used for the green compact can be used. Examples of the resin include a thermosetting resin such as an epoxy resin, a phenol resin, a silicone resin, and a urethane resin, a thermoplastic resin such as a polyphenylene sulfide (PPS) resin, a polyimide resin, and a fluorine resin, a room temperature curable resin, or a low temperature resin. A curable resin can be used. Injection molding is suitable for the molding of the core portion and the mounting portion made of the composite material.

The reactors according to the first to fourth embodiments include an in-vehicle converter (typically a DC-DC converter) mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, and a fuel cell vehicle, and a converter for an air conditioner. It can utilize suitably for the various converter of these, and the component of a power converter device.

DESCRIPTION OF SYMBOLS 1 (alpha), 1 (beta), 1 (gamma) Reactor 10 Combination 2 Coil 2a, 2b Winding part 2r Coil connection part 3 Magnetic core 31 Inner core part 32 Outer core part 32A Main body part 32B Projection molding part 3A, 3B Split core 3L Long projection part 3S Short Projection 3a Large Diameter 3b Small Diameter 3c Storage 3d Partition 31m Inner Core 32m Outer Core 30 Resin Cover 4 Fixed Member 41a, 41b Tubular Part 42 Connecting Part 43 Supporting Part 5 Flat Plate Member 5h Through hole 7 Bolt 9 Installation object 91 Placement surface 92 Base part 92h Mounting hole

Claims (9)

1. A reactor comprising a combination of a coil and a magnetic core disposed inside and outside the coil to form a closed magnetic path,
   The magnetic core is disposed outside the coil, and includes an outer core portion made of a material containing resin,
   A fixing member that is integrated with the resin and includes a plurality of cylindrical portions through which bolts that fix the combination to an installation target pass, and a block-shaped connecting portion that connects the plurality of cylindrical portions. Reactor equipped.
2. The reactor according to claim 1, wherein the outer core portion includes a protruding molded portion that includes a part of the fixing member.
3. The reactor according to claim 1 or 2, wherein the fixing member includes a pressure-supporting portion that extends in an outer peripheral direction from each end portion of the cylindrical portion and receives a tightening force of the bolt.
4. The reactor according to any one of claims 1 to 3, wherein the connecting portion includes a surface flush with an end surface of the cylindrical portion.
5. The reactor according to any one of claims 1 to 3, wherein the connecting portion is embedded in the resin.
6. The outer core portion includes a powder compact including soft magnetic powder, and a resin coating formed on the surface of the powder compact,
   The reactor according to any one of claims 1 to 5, wherein the fixing member is integrated with the resin coating portion.
7. The outer core portion is composed of a composite material including soft magnetic powder and resin,
   The reactor according to any one of claims 1 to 5, wherein the fixing member is integrated with a resin of the composite material.
8. The coil includes a pair of winding portions arranged side by side,
   The magnetic core includes a pair of inner core portions disposed inside the coil, and the outer core portion disposed outside the coil,
   The reactor according to any one of claims 1 to 7, wherein the plurality of cylindrical portions are present between extended surfaces of the outer side surfaces of the pair of inner core portions.
9. The reactor according to any one of claims 1 to 8, wherein the fixing member is made of metal.

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