JP2015201584A - reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor which does not need an adhesive for assembly of a magnetic core and achieves excellent assembly workability.SOLUTION: A reactor includes an assembly of a coil and a magnetic core having inner core parts disposed at the inner side of the coil and a pair of outer core parts which are connected with both ends of the inner core parts and form a closed magnetic circuit with the inner core parts. The reactor includes a frame member which encloses an outer periphery of the assembly so as to contact with outer end surfaces of the respective outer core parts. The frame member includes elastic pieces which press the outer end surfaces of the outer core parts to the inner core part side thereby fixing the inner core parts to the outer core parts.

Description

  The present invention relates to a reactor that is used in a vehicle-mounted DC-DC converter or a component of a power converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor that does not require an adhesive for assembling cores inside and outside the coil and is excellent in assembling workability between cores inside and outside the coil.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. The reactor is used in a converter mounted on a vehicle such as a hybrid vehicle. As the reactor, for example, there is one shown in Patent Document 1.

  The reactor of Patent Document 1 includes a coil having a pair of coil elements (winding elements), a pair of inner core parts fitted inside each coil element, and a pair of exposed core parts (outer core parts) exposed from the coils. ) (Core 0039, 0044). The inner core portion is configured by alternately arranging a plurality of core pieces and gap members and bonding them with an adhesive (same 0045). The exposed core portion is disposed so as to connect both end portions of the pair of inner core portions, and is joined to the inner core portion with an adhesive (same 0050).

JP 2011-199238 A

  As the adhesive is used, the assembly work of the magnetic core (reactor) becomes complicated. When joining the core piece and the gap material or the inner core portion and the outer core portion with an adhesive, it is necessary to apply and cure the adhesive for each contact portion. Therefore, it takes time and labor to assemble the magnetic core (reactor).

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a reactor that does not require an adhesive for assembling the cores inside and outside the coil and is excellent in assembling workability between the cores inside and outside the coil. It is to provide.

  The reactor which concerns on 1 aspect of this invention has a pair of outer core part which is connected to the both ends of a coil, the inner core part arrange | positioned inside a coil, and an inner core part, and forms a closed magnetic circuit with an inner core part A combination with a magnetic core is provided. The reactor includes a frame member that surrounds the outer periphery of the assembly so as to be in contact with the outer end surface of each outer core portion. And a frame member has an elastic piece which fixes an inner core part and the said outer core part by pressing the outer end surface of an outer core part to the inner core part side.

  The reactor does not require an adhesive for assembling the magnetic core and is excellent in assembling workability.

1 is a schematic perspective view showing a reactor according to Embodiment 1. FIG. It is a top view which shows the reactor which concerns on Embodiment 1. FIG. It is a disassembled perspective view which shows the outline of the union body with which the reactor which concerns on Embodiment 1 is equipped. It is a schematic perspective view which shows the frame member with which the reactor which concerns on Embodiment 1 is equipped. It is a schematic perspective view which shows the reactor which concerns on Embodiment 2. FIG. It is a top view which shows the reactor which concerns on Embodiment 3. FIG. It is a schematic perspective view which shows the reactor which concerns on Embodiment 4. It is a schematic perspective view which shows the reactor which concerns on Embodiment 5. FIG. FIG. 10 is a top view showing a reactor according to a fifth embodiment. It is a schematic perspective view which shows the reactor which concerns on Embodiment 6. FIG. It is a schematic perspective view which shows the reactor which concerns on Embodiment 7. FIG. 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit diagram which shows an example of a power converter device provided with a converter.

<< Description of Embodiments of the Present Invention >>
First, embodiments of the present invention will be listed and described.

  (1) A reactor according to an aspect of the present invention includes a coil, an inner core portion disposed inside the coil, and a pair of outer cores that are coupled to both ends of the inner core portion to form a closed magnetic path together with the inner core portion. A combination with a magnetic core having a portion is provided. The reactor includes a frame member that surrounds the outer periphery of the assembly so as to be in contact with the outer end surface of each outer core portion. And a frame member has an elastic piece which fixes an inner core part and the said outer core part by pressing the outer end surface of an outer core part to the inner core part side.

  According to said structure, an outer core part and an inner core part are united without using an adhesive agent by attaching the frame member provided with the elastic piece which presses an outer core part to an inner core part side to the outer periphery of an assembly. Can be fixed. Therefore, the complexity of the assembling workability of the magnetic core due to the use of the adhesive does not occur, so that the assembling workability of the magnetic core, and thus the assembling workability of the reactor can be improved. In particular, since the inner core portion 31 and the outer core portion 32 can be fixed simply by attaching the frame member 4 to the outer periphery of the combined body 10, the assembly workability of the magnetic core 3 is excellent. As described above, an adhesive is not used for fixing the inner core portion 31 and the outer core portion 32. However, when the entire reactor is viewed, an adhesive may be used for joining between other members. For example, when an inner core part is comprised with a core piece and a gap, a core piece and a gap material may be fixed with an adhesive agent.

  (2) As one form of the said reactor, it is mentioned that the elastic piece is curving so that it may protrude to the side which presses an outer core part.

  According to said structure, it is easy to press an outer core part to the inner core part side by curving an elastic piece as mentioned above. When attaching the frame member to the outer periphery of the assembly, the elastic piece can be easily spread outward, so that the inner region surrounded by the frame member can be expanded and the attachment of the frame member to the outer periphery of the assembly is easy.

  (3) As one form of the said reactor, it is mentioned that a frame member has an attaching part for attaching the fixing member which fixes an assembly to installation object.

  According to said structure, a reactor is installed by fixing the frame member which fixes an inner core part and an outer core part to the fixing location of installation object because a frame member has an attaching part for attaching a fixing member. Can be fixed to the target. In addition, a bolt is mentioned as a fixing member and an attachment part is provided with the insertion hole which penetrates the bolt.

  (4) As one form of the reactor, the frame member may include a relay piece that faces the side surface of the coil and is connected to the elastic piece. In this case, it is preferable that a gap is formed between the relay piece and the coil.

  According to the above configuration, since the gap is formed between the relay piece and the side surface of the coil, even if the relay piece (frame member) is made of a conductive material such as metal, the relay piece and the coil It is easy to improve the insulation between.

  (5) As one form of the reactor, when the relay piece is provided, the relay piece includes an insulating coating that is formed in a region facing the coil and insulates the coil.

  According to said structure, the insulation between a relay piece and a coil can be improved because a relay piece is provided with the said insulation coating.

  (6) As one form of the said reactor, an outer core part is provided with the side main-body part used as a magnetic path, and the side resin mold part which covers at least one part of the outer periphery of a side main-body part. In this case, it is preferable that the side resin mold part has a fitting groove for the elastic piece.

  According to said structure, since an outer core part is equipped with a side resin mold part, when attaching a frame member to an assembly, it can suppress that a frame member contacts a side main-body part, Therefore A side is accompanied with the contact. It is possible to suppress damage such as scraping of the main body. Moreover, since the side resin mold part is provided with the fitting groove for the elastic piece, it is easy to position the elastic piece with respect to the assembly.

  (7) As one form of the reactor, the reactor has a plurality of wedge portions interposed between turns so as to sandwich one or more turns of the coil from the outer periphery of the coil, and is interposed between the wedge portions. For example, a coil fixing member that restricts the movement of the turn is provided.

  According to said structure, since the movement of a turn can be controlled by providing a coil fixing member, the collision and rubbing of a turn and a magnetic core and the collision and rubbing of turns can be suppressed. Therefore, it is possible to reduce noise accompanying the collision and rubbing and damage to the coil insulation coating. The movement of the turn is associated with the vibration of the coil or the magnetic core during the operation of the reactor or the influence from the external environment, and mainly refers to the movement in the coil axis direction. The movement of the turn may include movement in the coil radial direction.

  (8) As one form of the reactor, the coil fixing member is interposed between the coil and the frame member, and is fixed to the coil by the frame member.

  According to said structure, a coil fixing member can be easily fixed to a coil.

  (9) As one form of the reactor, it is possible to cover at least a part of the frame-attached body in which the frame member is attached to the combined body, and to include a resin mold portion that integrally holds the combined body and the frame member. .

  According to said structure, while a combined body and a frame member can be hold | maintained integrally by a resin mold part, the mechanical protection and insulation of the coating location of the resin mold part in a frame-attached body can be improved.

<< Details of Embodiment of the Present Invention >>
Details of embodiments of the present invention will be described below with reference to the drawings.

Embodiment 1
[Overall structure of the reactor]
With reference to FIGS. 1-4, the reactor 1A of Embodiment 1 is demonstrated. 1 A of reactors are provided with the combination 10 of the coil 2 and the magnetic core 3 which has the inner core part 31 and the outer core part 32 which are arrange | positioned inside and outside the coil 2 and forms a closed magnetic circuit. The main feature of the reactor 1 </ b> A is that it includes the frame member 4 that fixes the inner core portion 31 and the outer core portion 32, and does not require an adhesive for assembling the cores 31 and 32. Hereinafter, the main characteristic part of reactor 1A, the structure of the related part, and the main effects will be described in order, and then each structure will be described in detail. Here, the installation target side of the combined body 10 is the installation side (lower side), and the opposite side is the opposite side (upper side). The same reference numerals in the figure indicate the same names.

[Composition of main features and related parts]
[Union]
(coil)
As shown in FIGS. 1 to 3, the coil 2 includes a pair of winding elements 2 a and 2 b formed by spirally winding a single continuous winding 2 w without a joint portion, and both winding elements 2 a and 2 b. And a connecting portion 2r for connecting the two. Each winding element 2a, 2b is a hollow cylindrical body having the same number of turns, and is arranged in parallel (side by side) so that the respective axial directions are parallel. The connecting portion 2r is configured such that a part of the winding is bent in a U shape on one end side of the coil 2 (the right side in FIGS. 1 to 3). The upper surface of the connecting portion 2r is substantially flush with the upper surface of the turn forming portion of the coil 2. Both end portions 2e of the winding 2w forming each winding element 2a, 2b are extended from the turn forming portion on the side opposite to the connecting portion 2r side. Both end portions 2e are connected to a terminal member (not shown), and an external device (not shown) such as a power source for supplying power to the coil 2 is connected via the terminal member.

(Magnetic core)
As shown in FIG. 3, the magnetic core 3 includes a pair of inner core portions 31 disposed inside the winding elements 2 a and 2 b and a pair of protrusions (exposed) from the coil 2 where the coil 2 is not disposed. The outer core part 32 is provided. The magnetic core 3 has an outer core portion 32 disposed so as to sandwich the inner core portion 31 that is spaced apart, and is formed in an annular shape by bringing the end surface of the inner core portion 31 and the inner end surface 32e of the outer core portion 32 into contact with each other. Is done. The inner core portion 31 and the outer core portion 32 form a closed magnetic circuit when the coil 2 is excited. The pair of inner core portions 31 and the pair of outer core portions 32 are each constituted by independent members. The inner core portion 31 and the outer core portion 32 are integrally connected by a frame member 4 described later. Therefore, no adhesive is required to connect the core portions 31 and 32. Specific configurations of the inner core portion 31 and the outer core portion 32 will be described later.

[Frame member]
The frame member 4 surrounds the outer periphery of the combined body 10 and integrally fixes the inner core portion 31 and the outer core portion 32. The frame member 4 surrounds the outer periphery of the combined body 10 so as to be in contact with the outer end surfaces 32o of the outer core portions 32 and to face both side surfaces of the coil 2. That is, the frame member 10 is attached to the combined body 10 substantially parallel to the installation target of the reactor 1A. The attachment location of the frame member 4 with respect to the height direction of the combined body 10 is a substantially intermediate position in the height direction of the outer core portion 32. This is because the inner core portion 31 and the outer core portion 32 can be pressed in a balanced manner in the vertical direction of the reactor.

  The shape of the frame member 4 is typically rectangular. The frame member 4 is in contact with the outer end surface 32o of each outer core portion 32 and a pair of elastic pieces 41 that press the outer core portion 32 toward the inner core portion 31 side, and a pair that faces the coil 2 and is connected to the elastic pieces 41. The relay piece 42 is provided. These two pieces 41 and 42 are connected by a mounting portion 43 to which a fixing member for fixing the reactor 1A to the fixing target is attached. The elastic piece 41 and the relay piece 42 form four pieces of the rectangular frame member 4, and the attachment portion 43 forms four corners of the rectangular frame member 4.

(Elastic piece)
The elastic piece 41 is in contact with the outer end surface 32o of each outer core portion 32 and presses the outer core portion 32 toward the inner core portion 31 as shown by arrows in FIGS. By this pressing, the inner core portion 31 and the outer core portion 32 can be fixed together without using an adhesive. The shape of the elastic piece 41 is not particularly limited as long as the outer core portion 32 can be pressed toward the inner core portion 31 side. Here, the shape of the elastic piece 41 is a curved shape that protrudes to the side that presses the outer core portion 32, that is, the inside of the frame member 4 in a state where the frame member 4 is attached to the combined body 10.

In order for the elastic piece 41 to press the outer core portion 32 toward the inner core portion 31 with the frame member 4 attached to the combined body 10, the elastic piece 41 before the frame member 4 is attached to the combined body 10 is as follows. Satisfying condition (1). (1) The length L ₄₁ (FIG. 4) between the pressed portions of the outer core portion 32 in each elastic piece 41 is the length L ₃₂ between the outer end surfaces 32 o of the outer core portion 32 along the coil axis direction. It is shorter than FIG. The reason for the condition (1) is that the length L ₄₁ of the elastic piece 41 is shorter than the length L ₃₂ of the outer core portion 32, so that when the frame member 4 is attached, the outer core portion 32 is moved to the inner side. This is because it is possible to increase the force of pressing toward the core portion 31 and to easily fix both the core portions 31 and 32.

Furthermore, it is mentioned that the elastic piece 41 before attaching the frame member 4 to the assembly 10 satisfies the following condition (2). (2) When attaching the frame member 4 to the union 10 and the two elastic pieces 41, as described above the length L ₄₁ of the elastic piece 41 is longer than the length L ₃₂ of the outer core portion 32 is elastically deformed Can be spread outward. The reason for the condition (2) is that, when the frame member 4 is attached to the combined body 10, it is necessary to prevent the elastic piece 41 from coming into contact with the outer core portion 32 so that the outer core portion 32 is not scraped. .

The shape of the elastic piece 4 is such that the length L ₄₁ of each elastic piece 41 is shorter than the length L ₃₂ of the outer core portion 32 before the frame member 4 is attached. 4 is a curved shape protruding inward. If it does so, when attaching the frame member 4 to the union body 10, the inner side area | region enclosed by the frame member 4 can be expanded, and it is easy to attach the frame member 4 to the union body 10. FIG. When attaching the frame member 4 to the combined body 10, both elastic pieces 41 are spread outside the frame member 4. This is because the length L ₄₁ of the elastic piece 41 can be made longer than the length L ₃₂ of the outer core portion 32 by, for example, extending both elastic pieces 41 so as to be linear. Further, when the frame member 4 is attached to the combined body 10, both the core portions 31 and 32 can be fixed by pressing the outer core portion 32 toward the inner core portion 31 side. Since the length L ₄₁ of the elastic pieces 41 is shorter than the length L ₃₂ of the outer core portion 32, whereby upon mounting the frame member 4 to the union 10, a force to the inside of both elastic pieces 41 both cores It is because it is made to act as the pressing force of the parts 31 and 32.

(Relay piece)
As described above, the relay piece 42 faces the winding elements 2a and 2b and is connected to the elastic piece 41. The relay piece 42 may be in contact with the winding elements 2a and 2b in a state where the frame member 4 is attached to the combined body 10, but is preferably not in contact with the winding elements 2a and 2b. That is, as shown in FIG. 2, the length L ₄₂ between the relay pieces 42 is longer than the width L _{cw of the} coil, and a gap is formed between the relay piece 42 and each winding element 2a, 2b. It is preferable. The coil width L _cw refers to the length along the parallel direction of the winding elements 2a and 2b. As will be described later, since the winding 2w constituting the winding elements 2a and 2b has an insulating coating, when the relay piece 42 (frame member 4) is formed of a conductive material such as metal, the relay piece 42 and each winding element are used. Even if 2a and 2b come into contact with each other, they can be insulated from each other. However, by making the relay piece 42 and the winding elements 2a and 2b non-contact, it is easy to improve the insulation between them. In addition, even if a pinhole is formed in the insulating coating of the coil 2, the coil 2 and the frame member 4 can be insulated by forming a gap.

  The shape of the relay piece 42 may be linear, but is preferably curved so as to protrude toward the winding elements 2a and 2b. By making the shape of the relay piece 42 the above-described curved shape, it becomes easier to attach the frame member 4 to the combined body 10 than when each relay piece 42 is linear. Here, the relay piece 42 has a curved shape protruding toward the winding elements 2a and 2b to such an extent that a gap is formed between the winding elements 2a and 2b. The edges of the portions of the relay piece 42 facing the side surfaces of the winding elements 2a and 2b are preferably rounded. If it does so, even if it contacts with winding element 2a, 2b, it is hard to damage winding element 2a, 2b.

  As for the relay piece 42, it is mentioned that the relay piece 42 before attaching the frame member 4 to the assembly 10 satisfies the following condition (1). (1) When the frame member 4 is attached, that is, when the elastic piece 41 is spread outward, it does not come into contact with the winding elements 2a and 2b. The reason for the condition (1) is that when the frame member 4 is attached to the assembly 10, the winding elements 2 a and 2 b can be prevented from being damaged by contact with the relay piece 42. If the insulation coating of the winding 2w constituting the winding elements 2a and 2b is damaged due to contact with the relay piece 42, the relay piece 42 (frame member 4) is made of a conductive material such as metal and the frame member 4 and each winding. This is because the turning elements 2a and 2b may be electrically connected.

(Mounting part)
The attachment portion 43 attaches a fixing member (not shown) that fixes the reactor 1A to the installation target. Here, as described above, the attachment portion 43 connects the pair of elastic pieces 41 and the pair of relay pieces 42, and forms four corners of the frame member 4 having a rectangular shape. The attachment portion 43 is formed with an insertion hole 43h through which a fixing member such as a bolt is inserted. The reactor 1A is fixed to the installation target by inserting the fixing member through the insertion hole 43h and fixing the fixing member to the installation target.

  The formation part in the height direction of the assembly 10 of the attachment part 43 may be selected as appropriate in accordance with the height of the fixing part to which the reactor 1A for fixing the attachment part 43 is to be installed. Here, the outer core portion 32 is provided at a substantially intermediate position in the height direction.

  The frame member 4 has no seam in the circumferential direction and is formed in series (continuously). That is, the elastic piece 41, the relay piece 42, and the attachment part 43 are integrally formed. Thereby, compared with a frame member configured by connecting a plurality of members, there is no connection portion that is likely to be a mechanical weak point, and therefore, the mechanical strength is excellent. In addition, the number of parts can be reduced and connection work of a plurality of members is unnecessary. Such a frame member 4 can be easily manufactured by punching a metal plate material described later.

  The width of the frame member 4 may be the same between the elastic piece 41 and the relay piece 42 or may be different. The thickness of the frame member 4 is preferably the same for the elastic piece 41, the relay piece 42, and the attachment portion 43 from the viewpoint of manufacturing workability of the frame member 4. The width and thickness of the frame member 4 may be appropriately adjusted according to the elastic deformability and mechanical strength required for the elastic piece 41 and the relay piece 42 and the constituent material of the frame member 4. The width refers to the length between the outer peripheral edge and the inner peripheral edge of the frame member 4, and the thickness refers to the length along the axial direction of the frame member 4.

  The material of the frame member 4 may be a metal from the viewpoint of elastic deformability and mechanical strength. Specific examples include stainless steel, copper and its alloys, aluminum and its alloys, magnesium and its alloys, and the like. In particular, nonmagnetic stainless steel is preferable so as not to affect the magnetic characteristics of the reactor.

[Effects of the main features of the reactor]
According to the reactor 1 </ b> A, the elastic piece 41 is attached to the outer periphery of the combined body 10 so that the elastic piece 41 is in contact with the outer end surface 32 o of the outer core portion 32, so that the elastic piece 41 becomes the outer core portion 32. The inner core part 31 and the outer core part 32 can be fixed by pressing toward the inner core part 31 side. Therefore, it is not necessary to use an adhesive for assembling the inner core portion core 31 and the outer core portion 32, and the assembly workability of both the cores 31, 32 due to the use of the adhesive does not occur. Therefore, the assembling workability of the magnetic core 3 and the assembling workability of the reactor 1A are excellent.

[Description of each configuration including other features]
[coil]
As the winding 2w constituting the coil 2, a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof can be suitably used. Examples of the shape of the conductor include a flat wire and a round wire. In this embodiment, the conductor is made of a rectangular copper wire and the insulation coating is made of enamel (typically polyamideimide), and each winding element 2a, 2b turns the covered wire into edgewise winding. Edgewise coil (FIG. 3). The end face shape of each winding element 2a, 2b is a shape obtained by rounding the corners of the rectangular frame. The end face shape can be appropriately changed such as a circular frame. The coil includes a pair of winding elements formed by spirally winding two independent windings, and a connecting member that connects both winding elements with a member independent of both winding elements. Also good.

[Magnetic core]
(Size / shape)
The inner core part 31 is arrange | positioned inside winding element 2a, 2b (coil 2) as mentioned above. The “inner core portion disposed inside the coil” means an inner core portion at least partially disposed inside the coil. For example, the case where the central portion of the inner core portion is disposed inside the coil and the vicinity of the end portion of the inner core portion is located outside the coil is also included in the “inner core portion disposed inside the coil”. That is, the axial length of the inner core portion 31 may be longer than the axial length of the winding elements 2a and 2b, and the end surface of the inner core portion 31 and the vicinity thereof are the end surfaces of the winding elements 2a and 2b. It may be exposed protruding.

  The shape of the inner core portion 31 and the shape of the outer core portion 32 can be selected as appropriate. Here, the shape of the inner core portion 31 is a rectangular parallelepiped shape as shown in FIG. 3, and the shape of the outer core portion 32 is substantially domed (inner end surface) as shown in FIGS. It is a columnar body having a deformed trapezoidal shape whose cross-sectional area decreases from 32e toward the outside. The shape of the outer core part 32 can also be a prismatic body, for example.

  The upper surface of the outer core portion 32 is flush with the upper surface of the inner core portion 32. On the other hand, the size of the outer core portion 32 is adjusted so that the lower surface of the outer core portion 32 is flush with the lower surface of the coil 2. Therefore, when the magnetic core 3 is formed in an annular shape, the lower surface of the outer core portion 32 protrudes from the lower surface of the inner core portion 31. Then, when the size of the inner core portion 31 in the reactor 1A is the same as that of the inner core portion in the conventional reactor, the reactor 1A reduces the amount of the constituent material of the magnetic core 3 (outer core portion 32) compared to the conventional reactor. It can be reduced, contributing to cost reduction and weight reduction. The lower surface of the combined body 10 is mainly composed of the lower surfaces of the two outer core portions 32 and the lower surface of the coil 2.

(Constituent materials)
The inner core portion 31 is a laminated body in which a plurality of core pieces 31m mainly composed of a soft magnetic material and gap members 31g made of a material having a lower relative permeability than the core pieces 31m are alternately laminated ( FIG. 4). The integration of the core piece 31m and the gap material 31g may be performed by the frame member 4 described above, or may be performed using an adhesive. Similar to the inner core portion 31, the outer core portion 32 is a core piece mainly composed of a soft magnetic material.

  Examples of the soft magnetic material that is the main component of each core piece constituting the inner core portion 31 and the outer core portion 32 include nonmetals such as iron, iron alloy, and ferrite. As the core piece, a molded body using the soft magnetic powder made of the soft magnetic material or a laminated body in which a plurality of magnetic thin plates having an insulating coating (for example, an electromagnetic steel plate typified by a silicon steel plate) are stacked can be used. As for the said molded object, the composite material containing a sintered compact, soft magnetic powder, and resin other than a compacting body (powder magnetic core) is mentioned. Even if the composite material has a complicated three-dimensional shape by using injection molding or the like, it can be easily molded. As a resin serving as a binder in the composite material, a thermosetting resin such as an epoxy resin or a thermoplastic resin such as a PPS resin can be used. The content of the soft magnetic powder in the composite material may be 20 volume% or more and 75 volume% or less when the composite material is 100 volume%. The balance is a non-magnetic material such as a non-metallic organic material such as a resin, ceramics such as alumina or silica, or a non-metallic inorganic material. Here, each core piece is a green compact.

  Specific materials for the gap material 31g include a nonmagnetic material such as alumina or unsaturated polyester, a nonmagnetic material such as PPS resin, and a magnetic material (an example of a magnetic material is a soft magnetic powder such as iron powder). Etc.

[Insulator]
The reactor 1 </ b> A can include an insulator 7 between the coil 2 and the magnetic core 3 for enhancing the insulation properties and positioning reliability (FIG. 3). The insulator 7 is a frame plate portion 72 that is interposed between a peripheral wall portion 71 that covers at least a part of the outer periphery of the inner core portion 31, and both end surfaces of the winding elements 2 a and 2 b and an inner end surface 32 e of the outer core portion 32. With. The peripheral wall portion 71 and the frame plate portion 72 are configured by independent members.

(Surrounding wall)
The peripheral wall portion 71 is interposed between the inner peripheral surface of the coil 2 and the outer peripheral surface of the inner core portion 31 and insulates the coil 2 from the inner core portion 31. Here, the peripheral wall 71 is constituted by a pair of divided pieces 711 and 712 having a cross section. The divided pieces 711 and 712 are not in contact with each other, and the divided pieces 711 and 712 are arranged only on a part of the outer peripheral surface of the inner core portion 31 (here, mainly the upper and lower surfaces of the inner core portion 31). . The peripheral wall portion 71 may be a cylindrical body that is disposed along the entire circumference of the outer peripheral surface of the inner core portion 31.

  The split pieces 711 and 712 are formed with windows penetrating the front and back. For example, in the form provided with the resin mold part 6 (see FIGS. 10 and 11) described in Embodiments 6 and 7 to be described later, the divided pieces 711 and 712 having the window part or the outer peripheral surface of the inner core part 31 are provided. By making the portion exposed from the peripheral wall portion 71, the contact area between the inner core portion 31 and the resin mold portion 6 can be increased. In addition, when the constituent resin of the resin mold portion 6 is poured, bubbles are easily removed, and the productivity of the reactors 1F and 1G (see FIGS. 10 and 11) is excellent. A concave portion 713 that is aligned with a convex portion 723 of the frame plate portion 72 described later is formed at the tip of the divided pieces 711 and 712.

(Frame plate part)
Each frame-like portion 72 is interposed between the end face of the coil 2 and the inner end face 32 e of the outer core portion 32, and insulates the coil 2 from the outer core portion 32. Each frame plate portion 72 includes a main body portion 721 formed of a B-shaped flat plate member having a pair of openings (through holes) into which the respective inner core portions 31 can be inserted. The coil side surface of the main body 721 is in contact with end surfaces (both end surfaces and lower end surfaces) excluding the upper end surfaces of the winding elements 2a and 2b (FIG. 1). That is, the frame plate portion 72 does not contact the upper end surface of the coil 2, and the upper end surface of the coil 2 is exposed from the frame plate portion 72. In addition, the main-body part 721 may be comprised with the flat plate member without the said opening part. In that case, the main body portion 721 can be used as a gap material between the inner core portion 31 and the outer core portion 32.

<Cylindrical part>
Each frame plate portion 72 includes a cylindrical portion 722 that facilitates insertion of the inner core portion 31 into the frame plate portion 72. The cylindrical portion 722 is provided so as to continue from the opening of the main body portion 721 and protrude toward the inner core portion 31. A convex portion 723 that is aligned with the concave portion 713 of the peripheral wall portion 71 is formed at the tip of the cylindrical portion 722.

<Partition section>
Each frame plate portion 72 includes a partition portion 724 that ensures insulation between the winding elements 2a and 2b. The partition portion 724 is provided so as to be interposed between the winding elements 2 a and 2 b between the peripheral wall portions 71 of the frame plate portion 72.

<Core positioning part>
Each frame plate portion 72 includes two projecting pieces 725 for positioning the outer core portion 32. The two projecting pieces 725 are formed at locations where the outer core portion 32 is sandwiched from both sides in the width direction below the inner end surface 32e side surface of the outer core portion 32.

<pedestal>
The frame plate portion 72 includes a pedestal 726 that protrudes from the upper surface to the outer core portion 32 side (the side opposite to the coil 2). The pedestal 726 of the frame plate portion 72 on the connection portion 2r side is interposed between the connection portion 2r and the outer core portion 32, and insulates both the connection portion 2r and the outer core portion 32.

(Material)
The constituent resin of the peripheral wall portion 71 and the frame plate portion 72 (insulator 7) is polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin, polybutylene terephthalate (PBT). ) Thermoplastic resins such as resins. Here, PPS resin is used.

[Manufacture of reactors]
The reactor 1 </ b> A can be manufactured through a process of manufacturing the combined body 10 → attaching the frame member 4 to the outer periphery of the combined body 10. First, the inner core part 31 is produced by integrating the core piece 31m and the gap member 31g with an adhesive. Subsequently, the peripheral wall portion 71 is disposed on the outer periphery of the inner core portion 31 and inserted into the coil 2 in that state. The frame plate portion 72 is fitted to both ends of the coil 2 while fitting the cylindrical portion 722 of the frame plate portion 72 to the inner core portion 31. Then, the outer core portion 32 is brought into contact with both end faces of the inner core portion 31. Thus, the combined body 10 is produced. Next, by expanding the elastic piece 41 of the frame member 4 to the outside, the area surrounded by the frame member 4 is expanded, the elastic piece 41 comes into contact with the outer end face 32o of the outer core portion 32, and the relay piece 42 is connected to the coil 2. The frame member 4 is attached to the outer periphery of the combined body 10 so as to face the side surface of the assembly. At this time, the outer core portion 32 and the inner core portion 31 are integrally fixed by the elastic piece 41 pressing the outer core portion 32 toward the inner core portion 31 side. Thus, the reactor 1A in which the frame member 4 is attached to the outer periphery of the combined body 10 can be manufactured.

<< Embodiment 2 >>
As illustrated in FIG. 5, as illustrated in FIG. 5, a reactor 1 </ b> B including a side main body part 32 b in which the outer core part 32 serves as a magnetic path and a side resin mold part 32 c that covers at least a part of the side main body part 32 b. can do. The side main body 32b is a core piece mainly composed of a soft magnetic material, like the outer core 32 of the first embodiment. The side resin mold part 32c mechanically protects the side main body part 32b.

  It is preferable that the covering region of the side resin mold portion 32c is at least a portion facing the elastic piece 41 in the side main body portion 32b. If it does so, when attaching the frame member 4 to the assembly 10, it can prevent that the elastic piece 41 contacts the side main-body part 32b, and can suppress damages, such as scraping of the side main-body part 32b by the contact. The covering region of the side resin mold portion 32c may be a portion facing the winding element 2a, 2b on the inner end surface 32e and a portion facing the connecting portion 2r on the upper surface in addition to the portion facing the elastic piece 41. preferable. If it does so, it will be easy to insulate between the side main-body part 32b and winding element 2a, 2b. The wider the covering area of the side resin mold part 32c, the more the side main body part 32b can be protected. The covering area of the side resin mold part 32c is the entire area excluding the contact points with the pair of inner core parts 31 in the side main body part 32b. It is particularly preferable to improve mechanical protection and insulation.

  The side resin mold part 32c preferably has a fitting groove 32t for the elastic piece 41 at a place where the elastic piece 41 is pressed. If it does so, it will be easy to position the elastic piece 41 and the frame member 4 with respect to the assembly 10. Here, the fitting groove 32t is an arcuate shape in which the shape of the reactor 1B seen through a plane (upper surface see-through) is surrounded by a string and an arc. The fitting groove 32t corresponds to the shape of the pressed portion of the outer core portion 32 in the elastic piece 41.

  As for the thickness of the side resin mold part 32c, 0.1 mm or more and 3 mm or less are mentioned. By setting the thickness of the side resin mold part 32c to 0.1 mm or more, the elastic piece 41 can be mechanically protected. In addition, the insulation with respect to the winding elements 2a and 2b can be improved. On the other hand, the side resin mold part 32c does not become too thick because the thickness of the side resin mold part 32c is 3 mm or less.

  The constituent material of the side resin mold part 32c is preferably a resin material having insulation and corrosion resistance, and more preferably a resin material having thermal conductivity. Examples of such a resin material include the same thermoplastic resin as the constituent resin of the insulator 7 described above. The resin material forming the side resin mold portion 32c may contain at least one ceramic filler selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide from the viewpoint of improving heat dissipation. Good. The side resin mold portion 32c can be formed by insert molding a resin material or immersing it in the resin material.

  The reactor 1B can be manufactured as follows. First, the outer core part 32 which coat | covered the side resin mold part 32c on the outer periphery of the side main-body part 32b is prepared. Thereafter, as described in the first embodiment, the combined body 10 is manufactured, and the frame member 4 is attached to the outer periphery of the combined body 10.

[Function and effect]
According to the reactor 1B, since the side resin mold part 32c is provided on the outer periphery of the side main body part 32b, the elastic piece 41 can be prevented from coming into contact with the side main body part 32b when the frame member 4 is attached to the combined body 10. The damage of the side main body 32b due to the contact can be suppressed. Moreover, since the side resin mold part 32c is provided with the fitting groove 32t, it is easy to position the frame member 4 with respect to the assembly 10, and the assembly workability of the reactor 1B can be improved.

<< Embodiment 3 >>
In the third embodiment, as shown in FIG. 6, an insulating coating 42c (two layers) is formed on the relay piece 42 in a region facing both side surfaces of each winding element 2a, 2b and insulates between each winding element 2a, 2b. It can be set as the reactor 1C provided with the frame member 4 which has a dashed-dotted line. Since the relay piece 42 includes the insulating coating 42c, the insulation between the relay piece 42 (frame member 4) and the coil 2 can be enhanced. In this case, the relay piece 42 can be brought into contact with the winding elements 2a and 2b.

  The covering region of the insulating coating 42c may be a region facing at least the central portion in the axial direction of each winding element 2a, 2b among the regions facing each winding element 2a, 2b of the relay piece 42. The relay piece 42 is curved so as to protrude toward the winding elements 2a and 2b, and the region closest to the winding elements 2a and 2b is a region facing the central portion in the axial direction of the winding elements 2a and 2b. It is. Of course, it is particularly preferable that the covering region of the insulating coating 42c is the entire region facing each winding element 2a, 2b of the relay piece 42.

  The constituent material of the insulating coating 42c may be the same type of resin (polyamideimide) as the insulating coating of the winding 2w constituting each winding element 2a, 2b, or the configuration of the insulator 7 and the side resin mold portion 32c (FIG. 5). The same thermoplastic resin as the resin may be used.

[Function and effect]
According to the reactor 1C, since the relay piece 42 includes the insulating coating 42c, the insulation between the relay piece 42 and the winding elements 2a and 2b can be enhanced.

<< Embodiment 4 >>
As a fourth embodiment, as shown in FIG. 7, a reactor 1 </ b> D including a coil fixing member 5 that restricts the movement of the coil 2 can be used. The reactor 1D of the fourth embodiment is the same as that of the first embodiment except that the coil fixing member 5 is provided. The following description will be focused on the configuration that differs from the first embodiment, and the description of the same configuration and effects as those of the first embodiment will be omitted.

[Coil fixing member]
The coil fixing member 5 regulates the turn movement (movement of the coil 2). The movement of the turn (movement of the coil 2) is accompanied by the vibration of the coil 2 and the magnetic core 3 during the operation of the reactor 1D or the influence from the external environment, and mainly refers to the movement in the coil axis direction. The movement of the turn may include movement in the coil radial direction. The coil fixing member 5 has a plurality of wedge portions 51 interposed between turns so as to sandwich one or more turns of the coil 2 from the outer periphery of the coil 2. Here, the shape of the coil fixing member 5 is a substantially [character-shaped thin plate shape whose both end portions are bent at a substantially right angle with respect to the central portion, and a plurality of wedge portions 51 are provided in the central portion.

  As shown in the lower right diagram and the lower left diagram in FIG. 7, the wedge portion 51 preferably has a triangular shape that tapers toward the tip side. This is because the wedge 51 is easy to insert between turns because the wedge 51 has a triangular shape that tapers toward the tip. The lower right diagram in FIG. 7 is an enlarged side view showing the vicinity of the central portion of the coil fixing member 5. The lower left diagram in FIG. 7 is an enlarged side view showing the vicinity of the base 726 of the reactor 1D.

  The wedge portion 51 may be provided so as to be interposed between the turns, or may be provided so as to be interposed between the turns so as to sandwich a plurality of turns. In either case, turn movement can be regulated. Specifically, when each wedge 51 is interposed between turns, the movement of the turn is restricted by sandwiching each turn between the wedges 51. On the other hand, when adjacent wedge portions 51 are interposed between turns so as to sandwich a plurality of turns, the movement of the turns is caused by narrowing the intervals between the plurality of turns between the wedge portions 51 by the wedge portions 51. Regulate by pressing turns. In particular, when the wedge portion 51 is interposed between the turns, it is easier to restrict the movement of the turn than when the wedge portion 51 is interposed so as to sandwich a plurality of turns. When the wedge portion 51 is interposed between turns so as to sandwich a plurality of turns, the wedge portion 51 is interposed between turns if the number of turns is the same after restricting the movement of the turn. As compared with the above, the axial length of the coil 2 can be shortened, and the reactor 1D can be downsized. Here, as shown in the lower right diagram of FIG. 7, the wedge portion 51 is provided so as to interpose a plurality of turns so as to sandwich a plurality of turns.

  In addition, as shown in the lower left diagram of FIG. 7, turns that are not sandwiched between the wedge portions 51, that is, turns (multiple turns) that are positioned on both ends of the coil with respect to the wedge portions 51 at both ends in the coil axial direction. Can be regulated by being sandwiched between the wedge portion 51 and the frame plate portion 72.

  The both end portions of the coil fixing member 5 are formed to be bent stepwise and are in contact with both end surfaces of the winding elements 2a and 2b. The movement of the turn can be suppressed by bringing the both end portions into contact with both end surfaces of the winding elements 2a and 2b and sandwiching the winding elements 2a and 2b from both ends in the axial direction. Hooks 52 that are hooked on the pedestals 726 of the frame plate portion 72 are formed at the tips of the both end portions of the coil fixing member 5. A wedge portion 51 is interposed between the turns so that both end portions come into contact with both end surfaces of the winding elements 2a and 2b, and the hook 52 is hooked on the base 726, so that the coil fixing member 5 is removed from the winding elements 2a and 2b. The state in which the wedge portion 51 is interposed between turns can be maintained by suppressing the separation. In addition, the coil 2 and the frame plate portion 72 can be fixed, and vibration between them can be suppressed.

  The number of coil fixing members 5 provided in each of the winding elements 2a and 2b may be single or plural. When the number of the coil fixing members 5 is singular, the coil fixing member 5 may be disposed on the upper surface, the side surface, or the lower surface of each winding element 2a, 2b. In particular, if the coil fixing member 5 is disposed at the upper surface or the side surface of each winding element 2a, 2b, the coil fixing member 5 is not interposed between the reactor 1D and the installation target. Increases sex. The form arrange | positioned on the side surface of each winding element 2a, 2b is demonstrated in Embodiment 5 mentioned later. On the other hand, when the number of the coil fixing members 5 is plural, the arrangement location of the coil fixing members 5 may be surfaces facing each other of the winding elements 2a and 2b. For example, when the number of the coil fixing members 5 is two, the coil fixing members 5 may be provided on the upper and lower surfaces of the winding elements 2a and 2b. Then, in addition to the movement of the turn in the coil axial direction, the shift of the turn in the radial direction and the shift of the coil 2 with respect to the inner core portion 31 can be suppressed.

  Examples of the constituent material of the coil fixing member 5 include the same thermoplastic resin as the resin material of the insulator 7 and the side resin mold portion 32c (FIG. 5) described above. This constituent material may contain the filler described above. If it does so, the heat dissipation of reactor 1D can be improved via the coil fixing member 5. FIG.

[Function and effect]
According to the reactor 1D, since the movement of the turn can be regulated by providing the coil fixing member 5, the collision and rubbing between the turn and the magnetic core 3 and the collision and rubbing between the turns can be suppressed. Therefore, it is possible to reduce noise accompanying the collision and rubbing and damage to the insulation coating of the coil 2.

<< Embodiment 5 >>
As Embodiment 5, as shown in FIGS. 8 and 9, a reactor 1 </ b> E in which the coil fixing member 5 is disposed between the side surfaces of the winding elements 2 a and 2 b (coil 2) and the frame member 4 can be used. . In the fifth embodiment, the configuration, shape, and location of the coil fixing member 5 are different from those in the fourth embodiment.

  The coil fixing member 5 includes a plurality of wedge portions 51, but does not include the hook 52 (FIG. 7) described in the fourth embodiment. The shape of the coil fixing member 5 is a rectangular flat plate. The coil fixing member 5 is fixed to the side surfaces of the winding elements 2a and 2b by the relay piece 42 pressing the coil fixing member 5 toward the winding elements 2a and 2b. For that purpose, adjusting the clearance gap between the relay piece 42 and each winding element 2a, 2b, adjusting the thickness of the main-body part of the coil fixing member 5 is mentioned. As described above, since the coil fixing member 5 can be fixed to the winding elements 2a and 2b by the relay piece 42, the coil fixing member 5 does not need to include the hook 52 (FIG. 7) described in the fourth embodiment. A fitting groove of the relay piece 42 may be formed at a location where the relay piece 42 of the coil fixing member 5 is pressed. Then, it is easy to position the relay piece 42 with respect to the coil fixing member 5. Like the fitting groove 32t (FIG. 5) described above, the fitting groove has a bow shape surrounded by a string and an arc, and may correspond to the shape of the pressed portion of the coil fixing member 5 in the relay piece 42.

[Function and effect]
According to the reactor 1E, since the coil fixing member 5 can be fixed to the coil 2 by the relay piece 42 (frame member 4), the coil fixing member 5 can be attached to the coil 2 simply by attaching the frame member 4 to the outer periphery of the combined body 10. Can be fixed. Therefore, the coil fixing member 5 can be easily fixed to the coil 2. Further, the insulation between the coil 2 and the relay piece 42 (frame member 4) can be enhanced by the coil fixing member 5. Therefore, the insulating coating 42c (FIG. 5) of the relay piece 42 described above may not be provided.

Embodiment 6
As Embodiment 6, as shown in FIG. 10, a resin mold portion that covers at least a part of the frame-attached body 100 in which the frame member 4 is attached to the combined body 10 and integrally holds the combined body 10 and the frame member 4. 6 can be a reactor 1F. In the sixth embodiment, the other configuration is the same as that of the first embodiment except that the resin mold portion 6 is provided. The following description will be focused on the configuration that differs from the first embodiment, and the description of the same configuration and effects as those of the first embodiment will be omitted.

[Resin mold part]
The resin mold portion 6 mechanically protects the covered portion in addition to integrally holding the combined body 10 and the frame member 4. The covering region of the resin mold part 6 may be an area excluding at least the attachment part 43. Here, the covering region of the resin mold portion 6 is a region excluding most of the elastic pieces 41 of the frame member 4 and the attachment portion 43. Specifically, the coating region of the resin mold portion 6 includes the outer periphery of the combination 10 excluding the contact portion with the elastic piece 41, the entire area of the relay piece 42, and the outer end surface 32o of the outer core portion 32 in the elastic piece 41. In the vicinity of the contact point. The resin mold portion 6 fills the space between the frame member 4 and the combined body 10. Specifically, the resin mold portion 6 is interposed between the winding elements 2 a and 2 b and the relay piece 42.

  Examples of the constituent material of the resin mold portion 6 include the same thermoplastic resin as that of the side resin mold portion 32c (FIG. 5) described above. The resin-molded portion 6 can be coated on the frame-attached body 100 by storing the frame-attached body 100 in an appropriate mold, and filling and curing the constituent material of the resin mold portion 6 in the mold. At this time, since the inner core portion 31 and the outer core portion 32 are integrally fixed to the frame-attached body 100 by the frame member 4, the frame-attached body 100 can be easily housed in the molding die.

[Function and effect]
According to the reactor 1F, since the outer periphery of the frame-attached body 100 is covered with the resin mold portion 6 in a state where the inner core portion 31 and the outer core portion 32 are fixed by the frame member 4, the frame member 4 is detached from the combined body 10. Therefore, the inner core part 31 and the outer core part 32 can be kept fixed by the elastic piece 41. In addition, the inner core portion 31 and the outer core portion 32 can be fixed by the resin mold portion 6 and the axial and radial movements of the coil 2 itself can be restricted. Furthermore, since the resin mold part 6 is interposed between the relay piece 42 and each winding element 2a, 2b, the insulation between the relay piece 42 (frame member 4) and each winding element 2a, 2b is provided. Enhanced.

<< Embodiment 7 >>
As a seventh embodiment, as shown in FIG. 11, in addition to the configuration of the sixth embodiment (including the frame member 4 and the resin mold portion 6), the reactor 1G including the coil fixing member 5 described in the fourth and fifth embodiments. It can be.

  The coil fixing member 5 includes a plurality of wedge portions 51, but does not include the hook 52 (FIG. 7) described in the fourth embodiment, as in the fifth embodiment. The shape of the coil fixing member 5 is a rectangular flat plate as in the fifth embodiment. The arrangement location of the coil fixing member 5 is the upper surface of each winding element 2a, 2b. The coil fixing member 5 is fixed to the winding elements 2a and 2b by the resin mold portion 6. For this purpose, the resin mold portion 6 is covered in a state in which the coil fixing member 5 is disposed on the upper surfaces of the winding elements 2 a and 2 b of the attachment portion 100. Thus, since the coil fixing member 5 can be fixed to the respective winding elements 2a and 2b by the resin mold portion 6, the coil fixing member 5 does not have to include the hook 52 (FIG. 7) described in the fourth embodiment. Good. In addition, although the coil fixing member 5 is provided on the upper surface of each winding element 2a, 2b, it can also be provided on the lower surface in addition to the upper surface of each winding element 2a, 2b. Then, in addition to the turn movement (coil axial direction), it is possible to suppress the deviation of the turn in the radial direction and the deviation of the coil 2 with respect to the inner core portion 31.

[Function and effect]
According to the reactor 1G, the coil fixing member 5 can be unfixed to the coil 2 by covering the outer periphery of the framed body 100 with the resin mold portion 6 while the coil fixing member 5 restricts the movement of the turn. Therefore, the regulation of the turn movement by the coil fixing member 5 can be maintained. Of course, the resin mold portion 6 can restrict the movement of the coil 2 itself in the axial direction and the radial direction. Moreover, by providing the coil fixing member 5, when forming the resin mold part 6, it can suppress that a turn moves by the press of a structural material at the time of filling to the shaping | molding die of the structural material.

Embodiment 8
In the reactors of the first to seventh embodiments, the energization conditions are, for example, maximum current (direct current): about 100 A to about 1000 A, average voltage: about 100 V to about 1000 V, use frequency: about 5 kHz to about 100 kHz, typically electric It can be used for a component part of a converter mounted on a vehicle such as an automobile or a hybrid car, or a component part of a power conversion device including this converter.

  A vehicle 1200 such as a hybrid vehicle or an electric vehicle is used for traveling by being driven by a main battery 1210, a power converter 1100 connected to the main battery 1210, and power supplied from the main battery 1210 as shown in FIG. Motor (load) 1220. The motor 1220 is typically a three-phase AC motor, which drives the wheel 1250 when traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, vehicle 1200 includes an engine in addition to motor 1220. In FIG. 12, although an inlet is shown as a charging location of the vehicle 1200, a form including a plug may be employed.

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

  As shown in FIG. 13, the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor L, and converts input voltage by ON / OFF repetition (switching operation). (In this case, step-up / down) As the switching element 1111, a power device such as a field effect transistor (FET) or an insulated gate bipolar transistor (IGBT) is used. The reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that prevents the change of the current to flow through the circuit. As the reactor L, the reactor of Embodiments 1-7 is provided. By providing a reactor having excellent assembly workability, the power conversion device 1100 and the converter 1110 can also be expected to improve the assembly workability.

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

  The present invention is not limited to these exemplifications, but is defined by the scope of the claims, and is intended to include all modifications within the scope and meaning equivalent to the scope of the claims. For example, a reactor including only one winding element can be used.

《Appendix》
The following additional notes are disclosed in relation to the embodiment of the present invention described above.

[Appendix 1]
A reactor comprising a coil and a magnetic core disposed inside and outside the coil to form a closed magnetic path,
A plurality of wedge portions interposed between turns so as to sandwich one or more turns of the coil from the outer periphery of the coil, and restricting the movement of the turns interposed between the wedge portions; A reactor including a coil fixing member.

  According to the reactor of appendix 1, since the movement of the turn can be restricted by providing the coil fixing member, it is possible to suppress the collision and rubbing between the turn and the magnetic core and the collision and rubbing between the turns. Therefore, it is possible to reduce noise accompanying the collision and rubbing and damage to the coil insulation coating. The movement of the turn is accompanied by the vibration of the coil or the magnetic core during the operation of the reactor or the influence from the external environment, and mainly refers to the movement in the coil axis direction.

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

1A, 1B, 1C, 1D, 1E, 1F, 1G reactor 10 combined body 100 framed body 2 coil 2a, 2b winding element 2r connecting part 2w winding 2e end part 3 magnetic core 31 inner core part 31m core piece 31g gap Material 32 Outer core portion 32e Inner end surface 32o Outer end surface 32b Side main body portion 32c Side resin mold portion 32t Fitting groove 4 Frame member 41 Elastic piece 42 Relay piece 42c Insulation coating 43 Mounting portion 43h Insertion hole 5 Coil fixing member 51 Wedge portion 52 Hook DESCRIPTION OF SYMBOLS 6 Resin mold part 7 Insulator 71 Peripheral wall part 711,712 Dividing piece 713 Concave part 72 Frame board part 721 Main body part 722 Cylindrical part 723 Convex part 724 Partition part 725 Protrusion piece 726 Base 1100 Power converter 1110 Converter 1111 Driving element 1112 Driving circuit L React 1120 inverter 1150 power feeding device converter 1160 auxiliary power converter 1200 vehicle 1210 main battery 1220 motor 1230 sub-battery 1240 auxiliaries 1250 wheels

Claims (9)

A combination of a coil and a magnetic core having an inner core portion disposed inside the coil and a pair of outer core portions that are connected to both ends of the inner core portion and form a closed magnetic path together with the inner core portion. A reactor with which
A frame member that surrounds the outer periphery of the assembly so as to be in contact with the outer end surface of each outer core portion;
The said frame member is a reactor which has an elastic piece which fixes the said inner core part and the said outer core part by pressing the said outer end surface of the said outer core part to the said inner core part side.   The reactor according to claim 1, wherein the elastic piece is curved so as to protrude to a side pressing the outer core portion.   The reactor according to claim 1, wherein the frame member has an attachment portion for attaching a fixing member that fixes the combination to an installation target. The frame member includes a relay piece facing the side surface of the coil and connected to the elastic piece,
The reactor according to any one of claims 1 to 3, wherein a gap is formed between the relay piece and the coil.   The reactor according to claim 4, wherein the relay piece includes an insulating coating that is formed in a region facing the coil and insulates the coil. The outer core portion is
A side body part that becomes a magnetic path;
A side resin mold part covering at least a part of the outer periphery of the side body part,
The reactor according to any one of claims 1 to 5, wherein the side resin mold portion has a fitting groove for the elastic piece.   A plurality of wedge portions interposed between turns so as to sandwich one or more turns of the coil from the outer periphery of the coil, and restricting the movement of the turns interposed between the wedge portions; The reactor of any one of Claims 1-6 provided with a coil fixing member.   The reactor according to claim 7, wherein the coil fixing member is interposed between the coil and the frame member, and is fixed to the coil by the frame member.   The resin mold part which covers at least one part of the frame attachment body to which the said frame member was attached to the said assembly, and hold | maintains the said assembly and the said frame member integrally is any one of Claims 1-8. The reactor according to item 1.

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