JP2019033135A - Manufacturing method of reactor - Google Patents

Abstract

To suppress the generation of a foreign material in a reactor to which a bus bar is fixed.SOLUTION: A manufacturing method of a reactor, having a core and a coil, includes: a primary mold formation step of coating an outer peripheral surface of the core with a resin, and manufacturing a primary mold formation body; an assembly step of assembling the coil to the primary mold formation body; a distribution step of distributing the bus bar connected to an end prat of the coil to a front surface part of the primary mold formation body; and a secondary molding formation step of coating the front surface part of the primary mold formation body to which the bus bar is distributed with the resin, and manufacturing a secondary mold formation body. The primary mold formation step includes a step of forming a movement regulation part for regulating the movement of the bus bar to the front surface part of the primary mold formation body. The secondary mold formation step includes a step of coating the bus bar in a state where the movement is regulated by the movement regulation part with the resin.SELECTED DRAWING: Figure 1

Description

  The technology disclosed in this specification relates to a method for manufacturing a reactor.

  An electric vehicle including a hybrid vehicle is equipped with a power conversion device that converts the output power of a battery into alternating current and supplies it to a traveling motor. The power converter may include a voltage converter circuit that boosts the voltage of the battery in addition to the inverter circuit that converts direct current to alternating current. The voltage converter circuit includes a plurality of switching elements and a reactor. Patent Documents 1 and 2 disclose an example of a reactor. Patent Document 1 discloses a technique in which a core is covered with a primary mold resin portion and a secondary mold resin portion is molded after a coil is assembled. Patent Document 2 discloses a technique for inserting a nut for fixing a bus bar to a resin body covering a core.

JP 2013-149841 A JP 2013-169075 A

  However, the techniques of Patent Documents 1 and 2 are not sufficient techniques in terms of fixing the bus bar. For example, when the bus bar is fixed on the resin body covering the core as in the technique of Patent Document 2, the bus bar and the resin body rub against each other when vibration is generated, and the resin may be scraped off to generate foreign matter. As described above, there is still room for improvement in the technology for fixing the bus bar in the reactor.

  The technology disclosed in the present specification has been made to solve the above-described problems, and an object thereof is to provide a technology for suppressing generation of foreign matters in a reactor to which a bus bar is fixed.

  The technology disclosed in this specification has been made to solve at least a part of the problems described above, and can be realized as the following forms.

  According to one form of the technology disclosed in the present specification, a method of manufacturing a reactor having a core and a coil is provided. This method for manufacturing a reactor includes a primary mold forming process, an assembling process, an arrangement process, and a secondary molding process. In the primary molding step, the outer peripheral surface of the core is covered with a resin to produce a primary mold molded body. In the secondary molding process, the coil is assembled to the primary molded body. In the arranging step, a bus bar connected to the end of the coil is arranged on the surface portion of the primary molded body. In the secondary molding step, the surface of the primary molded body on which the bus bars are arranged is covered with a resin to produce a secondary molded body. The primary mold forming step includes a step of forming a movement restricting portion for restricting the movement of the bus bar on the surface portion of the primary mold formed body. Further, the secondary mold forming step includes a step of covering the bus bar in a state where the movement is restricted by the movement restricting portion with a resin.

  According to the above manufacturing method, the bus bar is covered with the resin in a state in which the movement is restricted by the movement restricting portion formed on the surface portion of the primary molded body. It is hard to rub and can suppress the generation of foreign matter.

  The technology disclosed in the present specification can be realized in various modes. For example, a reactor in which a bus bar is fixed, a power conversion device including the reactor, a vehicle including the power conversion device, and a reactor It is realizable with forms, such as a manufacturing apparatus and the fixing method of a bus bar.

It is a flowchart which shows the manufacturing method of the reactor of 1st Embodiment. It is a figure for demonstrating the core prepared by a preparation process. It is a figure for demonstrating a primary mold formation process. It is a figure for demonstrating an assembly | attachment process. It is a figure for demonstrating an arrangement | positioning process. It is a figure for demonstrating a secondary mold formation process. It is the figure which showed the state which attaches components to the bus bar of a reactor. It is a figure for demonstrating the primary mold forming process of 2nd Embodiment.

<First Embodiment>
The manufacturing method of the reactor of this embodiment is demonstrated using FIGS. FIG. 1 is a flowchart showing a method for manufacturing a reactor according to the first embodiment. In the method for manufacturing a reactor according to the present embodiment, first, in a preparation step (step S10), a core used for the reactor is prepared.

  FIG. 2 is a diagram for explaining the core prepared in the preparation process. The core 2 prepared in this step is constituted by two core members 21 (21a, 21b) each having a substantially U shape. Each core member 21 (21a, 21b) has a substantially rectangular cross section, and includes two leg portions 22, 23 and a curved portion 25 that connects the leg portions. Rectangular end surfaces 26 and 27 are formed at the tip ends of the two leg portions 22 and 23, respectively. The two core members 21 (21a, 21b) are arranged so that the two end faces 26, 27 face each other, and the core 2 has a substantially ring-shaped outer shape as a whole. The core member 21 is manufactured by pressure molding by mixing a binder with resin-coated magnetic powder. The core member 21 may be produced by laminating a plurality of electromagnetic steel sheets punched into a substantially U shape and then integrally connecting them by pressure bonding or the like. After the core 2 is prepared, a primary mold forming step is performed in which the outer peripheral surface of the core 2 is covered with a resin to produce a primary mold formed body (FIG. 1: step S11).

  FIG. 3 is a diagram for explaining a primary mold forming step. In the primary mold forming step, the primary mold resin portion 3 (3a, 3b) is formed on the entire outer surface of the core member 21 (21a, 21b) except for the end faces 26, 27. Specifically, the primary mold resin portion 3a is formed on the entire outer surface of the core member 21a (FIG. 1) except for the end faces 26 and 27. Moreover, the primary mold resin part 3b is formed in the whole outer surface except the end surfaces 26 and 27 among the outer surfaces of the core member 21b (FIG. 1, FIG. 2). The primary mold resin part 3 (3a, 3b) can be produced, for example, by placing the core member 21 in a mold and then injection-molding a thermoplastic resin.

  The primary mold resin portion 3a and the primary mold resin portion 3b are respectively formed with a leg covering portion 31, a curved portion stomach portion 32, and a flange portion 33. The leg covering portion 31 covers the leg portions 22 and 23 (FIG. 2) of the core member 21. As will be described later, when the coil 4 (FIG. 4) is assembled, the coil 4 and the core member 21. Ensure an insulation distance between.

  The bent portion stomach portion 32 covers the bent portion 25 (FIG. 2) of the core member 21, and a flat surface portion 325 is formed. A convex portion 321 and a pin portion 322 are formed on the surface portion 325 of the primary mold resin portion 3a. The convex part 321 is a rectangular parallelepiped protrusion for fixing a bus bar 51 (FIG. 5) described later, and a slit part is formed between the convex part 321 and the surface part 325. The convex part 321 regulates the movement of the bus bar 51 by sandwiching the bus bar 51 in the slit part. The pin portion 322 is a substantially columnar protrusion for fixing a bus bar 52 (FIG. 5) described later, and protrudes upward from the surface portion 325. The pin portion 322 restricts the movement of the bus bar 52 by being inserted into a through hole 525 (FIG. 5) provided in the bus bar 52.

  Two terminal blocks 34 and 35 are further formed in the curved portion stomach portion 32 of the primary mold resin portion 3a. The terminal blocks 34 and 35 protrude in the direction along the surface portion 325 of the primary mold resin portion 3a, respectively, and have substantially circular flat portions 345 and 355 at the tip portions. Screw holes 341 and 351 are provided near the center of the flat portions 345 and 355.

  When the coil 4 (FIG. 4) is assembled, the flange portion 33 is disposed on both sides in the axial direction of the coil 4, and regulates the positions of both ends of the coil 4 by contacting both ends of the coil 4. Two concave portions 331 and 332 are formed in the flange portion 33 of the primary mold resin portion 3a. A bent portion 512 of the bus bar 51 (FIG. 5) is disposed in the recess 331 and restricts the movement of the bus bar 51. The concave portion 331 has a space portion surrounded by three wall portions, and a bent portion 512 of a bus bar 51 (FIG. 5) described later is disposed in this space portion. The movement of the bus bar 51 disposed in the recess 331 is restricted by contacting the three wall portions. Similar to the recess 331, the recess 332 has a space surrounded by three wall portions, and a bent portion 522 of a bus bar 52 (FIG. 5) described later is disposed in this space. The bus bar 52 disposed in the recess 332 is restricted from moving by contacting the three wall portions.

  As described above, the convex portion 321, the pin portion 322, and the concave portions 331 and 332 formed in the primary mold resin portion 3 a are the bus bars 51 and 52 (FIG. 5) arranged on the surface portion 325 of the primary mold resin portion 3 a. ) Functions as a movement restricting unit that restricts movement of Hereinafter, the entire core member 21 covered with the primary mold resin portion 3 (primary molded product) is also referred to as “primary mold molded body 10”. After the primary molded body 10 is produced, an assembling step for assembling the coil 4 to the primary mold body 10 is performed (FIG. 1: step S12).

  FIG. 4 is a diagram for explaining the assembly process. In the assembly process, first, two coils 4 (4a, 4b) are prepared. The two coils 4 (4a, 4b) are electrically connected in series, and each is constituted by an edgewise coil that is formed in advance by winding a rectangular conductive wire with an insulating film treated with enamel or the like into a rectangle. Has been. The ends (conductive wire ends) 41 and 42 of the conductive wires of the two coils 4 (4a and 4b) protrude upward from the coil 4, respectively.

  After preparing the two coils 4 (4a, 4b), the leg covering portion 31 of the primary mold resin portion 3a is inserted from one side of the through hole 45 formed by the inner peripheral portion of the coil 4, and from the other side. The leg portion covering portion 31 of the primary mold resin portion 3b is inserted. The leg covering portion 31 of the primary mold resin portion 3a and the leg covering portion 31 of the primary mold resin portion 3b are connected inside the coil 4 so that the end faces 26 and 27 of the core member 21 face each other. . After assembling the coil 4 to the primary molded body 10, an arrangement step of arranging the bus bars 51, 52 on the surface portion 325 of the primary mold body 10 is performed (FIG. 1: step S <b> 13).

  FIG. 5 is a diagram illustrating the arrangement process. In the arrangement step, first, two bus bars 51 and 52 are prepared. The bus bar 51 is formed of an elongated flat plate member, and has a shape that is bent at a substantially right angle to the main surface side of the bus bar 51 at the bent portion 512. The front end portion 511 of the bus bar 51 has a circular shape, and an opening is formed near the center. The rear end portion 513 of the bus bar 51 extends in a direction orthogonal to the extending direction of the front end portion 511.

  The bus bar 52 is formed of a flat plate member that is bent at a right angle at two locations. The bent portion 522 has a shape that is bent substantially at a right angle on the main surface side of the bus bar 52. The front end 521 of the bus bar 52 has a circular shape, and an opening is formed near the center. The rear end portion 523 of the bus bar 52 extends in a direction orthogonal to the extending direction of the front end portion 521.

  After the two bus bars 51 and 52 are prepared, the prepared bus bars 51 and 52 are respectively arranged on the surface portion 325 of the primary mold resin portion 3a. When the bus bar 51 is disposed on the surface portion 325, the rear end portion 513 of the bus bar 51 is brought into contact with the conducting wire end portion 41 of the coil 4, and the front end portion 511 of the bus bar 51 is disposed on the flat portion 345 of the terminal block 34. Further, the bent portion 512 of the bus bar 51 is disposed in the concave portion 331 of the flange portion 33, and a part of the bus bar 51 is sandwiched between the slit portions of the convex portion 321. By disposing the front end portion 511 of the bus bar 51 on the flat portion 345 of the terminal block 34, an opening provided in the front end portion 511 of the bus bar 51 and a screw hole 341 provided in the flat portion 345 of the terminal block 34 Communicate. Further, the bent portion 512 of the bus bar 51 is disposed in the concave portion 331 of the flange portion 33, and a part of the bus bar 51 is sandwiched between the slit portions of the convex portion 321, thereby restricting the movement of the bus bar 51.

  When the bus bar 52 is disposed on the surface portion 325, the rear end portion 523 of the bus bar 52 is brought into contact with the conducting wire end portion 42 of the coil 4, and the front end portion 521 of the bus bar 52 is disposed on the flat portion 355 of the terminal block 35. Further, the bent portion 522 of the bus bar 52 is disposed in the concave portion 332 of the flange portion 33, and the through hole 525 of the bus bar 52 is engaged with the pin portion 322 provided in the surface portion 325. By disposing the front end portion 521 of the bus bar 52 on the flat portion 355 of the terminal block 35, an opening provided in the front end portion 521 of the bus bar 52 and a screw hole 351 provided in the flat portion 355 of the terminal block 35 are provided. Communicate. Further, by disposing the bent portion 522 of the bus bar 52 in the concave portion 332 of the flange portion 33 and engaging the through hole 525 of the bus bar 52 with the pin portion 322 provided in the surface portion 325, the movement of the bus bar 52 is restricted. The As described above, after the two bus bars 51 and 52 are arranged on the surface portion 325, a secondary mold forming step for producing a secondary mold formed body is performed (FIG. 1: step S14).

  FIG. 6 is a diagram for explaining the secondary mold forming step. In the secondary molding process, the secondary mold resin portion 6 is formed on the outer surface of the primary molded body 10 to which the coil 4 and the bus bars 51 and 52 are attached. The secondary mold resin portion 6 can be produced, for example, by placing the primary mold molded body 10 to which the coil 4 and the bus bars 51 and 52 are attached in a mold and then injection-molding a thermoplastic resin. The secondary mold resin portion 6 may be the same type of resin as the primary mold resin portion 3 or may be different.

  The secondary mold resin portion 6 covers the entire outer surface other than the flat portions 345 and 355 of the terminal blocks 34 and 35 among the outer surface of the primary mold molded body 10. Further, the secondary mold resin portion 6 covers a portion other than a part of the outer surface of the coil 4. The coil 4 is fixed to the primary molded body 10 by the secondary mold resin portion 6 and becomes an integrated body with the primary molded body 10. The conducting wire end portions 41 and 42 protrude from the secondary mold resin portion 6.

  The bus bar 51 is covered with the secondary mold resin portion 6 except for the front end portion 511 and the rear end portion 513. Since the movement of the bus bar 51 arranged on the primary mold resin portion 3 (FIG. 5) is restricted by the concave portion 331 and the convex portion 321 provided in the primary mold resin portion 3, formation of the secondary mold resin portion 6 is performed. At the time (injection molding), positional deviation is suppressed. The bus bar 52 is covered with the secondary mold resin portion 6 except for the front end portion 521 and the rear end portion 523. Since the bus bar 52 arranged on the primary mold resin portion 3 (FIG. 5) is restricted in movement by the concave portion 332 and the pin portion 322 provided in the primary mold resin portion 3, as with the bus bar 51, the secondary When the mold resin portion 6 is formed (injection molding), positional deviation is suppressed.

  When the two bus bars 51 and 52 are covered with the secondary mold resin portion 6, they are inserted between the primary mold resin portion 3 and the secondary mold resin portion 6. In other words, the two bus bars 51, 52 are integrated with the primary molded body 10 by the secondary mold resin portion 6. Accordingly, even if vibration is applied to the bus bars 51 and 52, the bus bars 51 and 52 are not easily displaced with respect to the primary mold resin part 3 and the secondary mold resin part 6. The whole (secondary molded product) in which the primary mold molded body 10 is covered with the secondary mold resin portion 6 is also referred to as “secondary mold molded body 15”. The secondary mold molded body 15 is a finished product of the reactor, and the production of the reactor is completed by obtaining the secondary mold molded body 15.

  FIG. 7 is a diagram for explaining a state in which components are attached to the completed bus bar 51 of the reactor. FIG. 7 illustrates a cross-sectional shape in the vicinity of the terminal block 34. Here, the case where the bus bar 71 extended from the other party is attached to the bus bar 51 of the reactor will be described as an example. Since the front end portion 511 of the bus bar 51 is not covered with the secondary mold resin portion 6 and is exposed, the bus bar 71 extending from the mating side can be disposed on the upper surface of the bus bar 51. At this time, the opening provided in the bus bar 71 is arranged so as to communicate with the opening of the bus bar 51 and the screw hole 341. Then, the bus bar 71 can be fixed to the terminal block 34 in a state in which the bus bar 71 is electrically connected to the bus bar 51 by inserting the bolt 72 into the portion where they communicate.

<Example of effects of this embodiment>
According to the reactor manufacturing method of the present embodiment described above, the bus bars 51 and 52 are moved by the movement restricting portions such as the convex portions 321 and the pin portions 322 formed on the surface portion 325 of the primary molded body 10. It is covered with the secondary mold resin in a regulated state. Therefore, the reactor manufactured by the manufacturing method of the present embodiment is less likely to rub between the bus bars 51 and 52 and the resin (primary mold resin and secondary mold resin) even when vibration is generated, and the generation of foreign matter due to the resin being scraped. Can be suppressed.

Second Embodiment
FIG. 8 is a diagram for explaining a primary molding process of the second embodiment. In the primary mold molded body 10 (FIG. 5) molded by the primary mold molding process of the first embodiment, the convex portion 321 and the pin portion 322 are provided on the surface portion 325. However, the primary molded body formed in the primary mold forming step may have another shape as a movement restricting portion that restricts the movement of the bus bars 51 and 52.

  For example, as shown in FIG. 8, guide grooves 326 and 327 are formed in the surface portion 325 of the primary molded body 10A of the second embodiment. The bus bar 51 is disposed inside the guide groove 326, and movement is restricted by the side wall portion inside the guide groove 326. The bus bar 52 is disposed inside the guide groove 327, and movement is restricted by the side wall portion inside the guide groove 326. Even in such a configuration, since the movement of the bus bars 51 and 52 can be restricted by the guide grooves 326 and 327, the same effect as in the first embodiment can be obtained.

<Modification of this embodiment>
The technology disclosed in the present specification is not limited to the above-described embodiment, and can be implemented in various modes without departing from the gist thereof. For example, the following modifications are possible.

[Modification 1]
The movement restriction part of the primary mold molded body 10 shown in the first embodiment and the movement restriction part of the primary mold molded body 10A shown in the second embodiment may be used in appropriate combination. For example, the primary molded body 10 of the first embodiment may include guide grooves 326 and 327 in addition to the convex portions 321 and the pin portions 322 on the surface portion 325. Further, the primary molded body 10 includes a convex portion 321 and a guide groove 327 on the surface portion 325, and may not include the pin portion 322.

  Although the embodiments have been described in detail above, these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes of the above-described embodiment. The technical elements described in this specification or the drawings exhibit technical usefulness alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. Further, the technology described in this specification or the drawings achieves a plurality of objects at the same time, and has technical usefulness by achieving one of the objects.

DESCRIPTION OF SYMBOLS 2 ... Core 3 ... Primary mold resin part 4 ... Coil 6 ... Secondary mold resin part 10 ... Primary mold molded object 15 ... Secondary mold molded object 21 ... Core member 41, 42 ... Conductor end part 51, 52 ... Bus bar 321 ... Convex part 322 ... Pin part 325 ... Surface part 326, 327 ... Guide groove 331, 332 ... Concave part

Claims (1)

A method of manufacturing a reactor having a core and a coil,
A primary mold forming step in which the outer peripheral surface of the core is coated with a resin to produce a primary molded body,
An assembling step for assembling the coil to the primary molded body;
An arrangement step of arranging a bus bar connected to an end of the coil on a surface portion of the primary molded body,
A secondary mold forming step of producing a secondary mold molded body by coating a surface portion of the primary mold molded body in which the bus bar is disposed with a resin,
The primary mold forming step includes a step of forming a movement restricting portion for restricting the movement of the bus bar on the surface portion of the primary mold formed body,
The method of manufacturing a reactor, wherein the secondary mold forming step includes a step of covering the bus bar in a state in which movement is restricted by the movement restriction unit with a resin.

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