JP4725785B2 - Reactor and manufacturing method thereof - Google Patents

Description

  The present invention relates to a reactor including a core and a coil disposed on the outer periphery of the core, and a method for manufacturing the reactor. In particular, the present invention relates to a reactor that can stably perform relative positioning between a core and a coil, and can easily fill a combination of a core and a coil housed in a case with a sealing material, and a method for manufacturing the reactor. is there.

  In recent years, hybrid vehicles have been put into practical use. A hybrid vehicle is a vehicle that includes an engine and a motor as drive sources and travels using one or both of them. In such a hybrid vehicle, for example, as shown in FIG. 6, a battery 110, an inverter 120, and a traveling three-phase AC motor 130 are used.

  Among them, the inverter 120 includes a converter unit 121 that performs direct current step-up / step-down and an inverter unit 122 that performs mutual conversion between direct current and alternating current. For example, the converter unit 121 boosts the battery voltage of about 200 V to a maximum of about 500 V during driving and supplies power to the inverter unit 122. During regeneration, the converter unit 121 converts the direct current output from the motor 130 via the inverter unit 122 into the battery 110 The voltage is reduced to a voltage suitable for the battery 110 and the battery 110 is charged. Further, the inverter unit 122 converts the direct current boosted by the converter unit 121 into a predetermined alternating current during driving and supplies power to the motor 130, and converts the alternating current output from the motor 130 into direct current during regeneration. Is output.

  The converter 121 boosts the voltage by repeating ON / OFF (switching operation) of the amplifying element 121A such as an FET. One of the components is a reactor 121B having a coil. Reactor 121B has the function of smoothing the change when the current is going to increase or decrease due to an external factor such as switching operation, utilizing the property of the coil that tries to prevent the change of the current to flow through the circuit. . As shown in FIG. 7, the main material constituting the reactor 121B includes a core 100 and a coil 200, which are housed in a case 300 and mounted in an inverter assembly. After housing the combination of the core 100 and the coil 200 in the case 300, a sealing material (potting material, not shown) is used for the purpose of preventing the rust of the core 100 and the coil 200 and preventing noise caused by these vibrations. ) Is filled.

  As the core 100, a pair of quadrangular columnar first cores 101 (see FIG. 8 (a)) and a pair of U-shaped second cores 102 (see FIG. 8 (d))) are combined to form an annular shape. Things are often used. Such a combination of the core 100 and the coil 200 is obtained as follows. First, the bobbin 110 that performs relative positioning of the core 101 and the coil 200 is disposed so as to cover the entire surface of the four surfaces covered by the winding portion of the coil 200 on the outer peripheral surface of the first core 101 (FIG. 8). (See (b)). Next, the first core 101 including the bobbin 110 is housed in a winding portion of the coil 200 in which a conducting wire is wound in advance (see FIG. 8C). Then, the end faces of the second core 102 are brought into contact with the two end faces (two faces where the bobbin 110 is not disposed) of each first core 101 exposed from the opening of the winding part, and both the cores 101 and 102 are joined. Thus, a combination as shown in FIG. 7 is obtained.

  The bobbin 110 shown in FIG. 8 has a configuration that forms a cylindrical body by combining divided pieces 110a and 110b having a cross section. As another member that performs relative positioning of the core and the coil, Patent Document 1 describes a cylindrical bobbin that covers the entire four surfaces covered by the coil on the outer peripheral surface of the quadrangular columnar core. Patent Document 2 describes a jig including a plurality of insertion pieces arranged between conductive wires forming a coil and a base piece for connecting the insertion pieces.

JP 2003-124039 A JP 2003-77746 A

  When the member that performs relative positioning between the core and the coil is configured to cover all the surfaces covered by the coil on the outer peripheral surface of the core like the bobbin shown in FIG. 8 or the bobbin described in Patent Document 1, A portion of the core covered with the bobbin cannot sufficiently contact the sealing material, and the sealing material may not be sufficiently filled. Due to poor filling, the core and coil are rusted and noise is generated. Therefore, if it is going to contact a sealing material enough with a core, filling time will take and productivity will fall.

  The jig described in Patent Document 2 also includes an insertion piece, which prevents the contact between the core and the sealing material in the same manner as the bobbin, and may cause insufficient filling of the sealing material. In particular, since the gap between the conductive wires forming the coil with the inserted piece is closed, the sealing material cannot be infiltrated using this gap.

  In addition, as described above, a jig having a bobbin and an insertion piece that covers the entire surface of the core covered with the coil on the outer peripheral surface of the core has a complicated shape, resulting in high costs and increased reactor productivity. Reduce.

  Accordingly, a main object of the present invention is to provide a reactor that can sufficiently perform relative positioning between a core and a coil, is easily filled with a sealing material, and is excellent in manufacturability. Moreover, the other object of this invention is to provide the manufacturing method of the reactor suitable for manufacture of such a reactor.

  The reactor according to the present invention includes the positioning member only in a part of the gap formed between the outer peripheral surface of the core and the inner peripheral surface of the coil winding portion, and specifies the material and shape of the positioning member. Achieve the goal. The specific configuration is as follows.

The reactor according to the present invention includes a core and a coil disposed on the outer periphery of the core, and these are accommodated in a case and sealed with a sealing material. A spacer for positioning the core and the coil relative to each other is disposed in a part of the gap formed between the inner peripheral surface of the turning portion. In addition, no spacer is provided in the remaining portion of the gap. The spacer satisfies at least one of the following conditions (1) and (2).
(1) Made of the same material as the sealing material
(2) Made of rectangular plate

Moreover, the manufacturing method of the reactor of this invention achieves the said objective by arrange | positioning a positioning member only to a part of location covered with the winding part of a coil in the outer peripheral surface of a core. Specifically, the present invention includes an arranging step of arranging a coil on the outer periphery of the core, a housing step of housing the core including the coil in a case, and a sealing step of filling the case with a sealing material. This is a manufacturing method for a reactor. In particular, the manufacturing method of the present invention includes the following steps before the placement step.
A step of attaching a spacer for relative positioning of the core and the coil to a part of the portion covered with the coil winding portion on the outer peripheral surface of the core and not attaching a spacer to the remaining portion of the same portion

  The reactor obtained from the reactor of the present invention and the manufacturing method of the present invention includes the positioning member (spacer), so that the relative positioning of the core and the coil can be reliably performed. In particular, in the reactor obtained from the reactor of the present invention and the manufacturing method of the present invention, one of the gaps formed between the surface covered by the coil winding portion and the inner peripheral surface of the coil winding portion of the outer peripheral surface of the core. Since the positioning spacer is provided only in the portion, the portion where the spacer is not disposed is exposed to the inner peripheral space of the winding portion of the outer peripheral surface of the core that creates the gap before the sealing material is filled. It becomes a state. With such a configuration, when the sealing material is filled, the core and the sealing material can sufficiently come into contact with each other in the space where the spacer is not arranged in the gap, and the sealing material is poorly filled. Realize the reduction. Furthermore, the filling time can be shortened, and the productivity can be improved.

  In particular, in the reactor of the present invention, the spacer is formed of the same type of material as the sealing material, so that the familiarity between the sealing material and the spacer is good, and the filling property of the sealing material can be improved. Can be improved. Further, in the reactor of the present invention, since the spacer is arranged only in a part of the gap, the shape of the positioning member can be simplified as compared with the conventional bobbin and jig, and the positioning member can be easily manufactured. Therefore, manufacturability as a whole reactor can be improved. In addition, the cost can be reduced by simplifying the shape of the positioning member.

  Furthermore, in the manufacturing method of the reactor of the present invention, the spacer is attached to the outer peripheral surface of the core, and therefore, the spacer can be easily mounted as compared with the case where the positioning member is attached to the inner peripheral surface of the coil winding portion. The productivity of the reactor as a whole can be improved.

Hereinafter, the present invention will be described in more detail.
This invention reactor is accommodated in a case in the state which arranged the coil on the outer periphery of the core, and these core and coil are sealed with a sealing material. As the core, a core made of a magnetic material such as an iron-based material such as silicon steel can be used. Moreover, you may utilize as a core the thing comprised by inserting | pinching the gap which consists of nonmagnetic materials, such as a ceramic, between the members which consist of magnetic materials. Further, the core may be obtained by combining a plurality of divided pieces and joining them together with an adhesive or the like. Examples of the shape of the core include a ring formed by combining a pair of quadrangular columnar first cores and a pair of U-shaped columnar second cores having a surface in contact with one surface of the first cores. When this annular core is used, the coil is disposed on the outer periphery of the first core.

  As the coil, a conductive wire having an insulating coating is typically used. Specifically, for example, a coil in which a rectangular conductor having a rectangular cross section is wound in an edgewise manner can be used.

  The combined body including the core and the coil includes a spacer that performs relative positioning between the core and the coil. The spacer fills a gap formed between the outer peripheral surface of the core and the inner peripheral surface of the coil winding portion in a state where the core is housed in the coil winding portion, and the core does not move unnecessarily in the winding portion. Used to make As described above, the coil is disposed on the outer periphery of the core after winding a conducting wire in advance. Therefore, the cross-sectional area of the coil winding portion is slightly larger than the cross-sectional area of the core so that the core can be easily accommodated. A gap is formed between the surface and the outer peripheral surface of the core covered with the coil winding portion. Due to this gap, the relative positioning between the core and the coil is not stable. Therefore, in order to stabilize the relative positioning of the core and the coil, the reactor of the present invention includes a spacer. If the relative positioning between the core and the coil is stable, it is not necessary to cover the entire outer peripheral surface of the core covered with the coil with the positioning member, as in the conventional case. In addition, since the entire outer peripheral surface of the core covered with the coil is covered with the positioning member as in the conventional case, problems such as poor filling of the sealing material also occur. Therefore, in the present invention, the spacer is arranged only in a part of the gap formed between the inner circumferential surface of the coil and the outer circumferential surface of the core, and the spacer is not arranged in the remaining portion of the gap.

  For example, when the core and the coil are housed in the case, the spacer is disposed in a space located between the inner peripheral surface of the coil and the outer peripheral surface of the core. And the gravity stabilizes the core position. For example, when using the cyclic | annular core which combines the 1st core mentioned above and a 2nd core as a core, two surfaces and winding which oppose among four surfaces covered with the winding part of a coil in a 1st core. Compared to the case where a spacer is provided in the gap created between the inner peripheral surface of the turning part and a spacer provided only in the gap created between one of the four faces and the inner peripheral surface of the winding part. Thus, the position of the core is easy to stabilize, and the core is less likely to be unevenly distributed with respect to the winding part. If a spacer is provided in a gap created between three or four of the four surfaces and the inner peripheral surface of the winding portion, the spacer is further stabilized. When spacers are provided in these gaps, the size of one spacer (area covering one surface of the core) is the size (area) of one surface of the core in consideration of the contact between the sealing material and the core described later. And the entire four surfaces of the core are not covered with spacers. A plurality of spacers smaller than one surface of the core may be arranged on the surface, but the number of spacers and the size of the spacers are adjusted so that the entire surface is not covered with the spacers. By such adjustment, the entire four surfaces of the core are not covered with the spacer. Moreover, you may distribute | arrange a spacer to the clearance gap created between the corner | angular part which two adjacent surfaces make among the four surfaces of the said 1st core, and its vicinity and the inner peripheral surface of a winding part. At this time, if the spacers are also disposed in the gap formed between the corner that is diagonal to one corner and the vicinity thereof and the inner peripheral surface of the winding portion, the position of the core can be further stabilized. it can. Spacers may be arranged in the gaps formed between the four corners and the vicinity thereof and the inner peripheral surface of the winding part. Also in this case, the size of the spacer may be appropriately selected so that the entire four surfaces of the core are not covered with the spacer.

  One spacer or a plurality of spacers may be provided for one core. Further, only one spacer may be provided in the gap formed between one surface of the first core and the inner peripheral surface of the winding portion, or a plurality of spacers may be provided. Further, only one spacer may be provided in the gap formed in the corner of the core, or a plurality of spacers may be provided. When a plurality of spacers are provided, the size of each spacer and the number of spacers are selected so that the entire outer peripheral surface of the core covered with the coil winding portion is not covered with the spacers as described above.

  The shape of the spacer allows relative positioning of the core and the coil, does not cover the entire outer peripheral surface of the core covered by the coil winding portion, and does not cover the outer peripheral surface of the core and the winding portion of the coil. Various shapes can be used as long as they have a thickness capable of closing the gap formed between the inner peripheral surface and the inner peripheral surface. For example, various shape plate materials such as a rectangular plate material having a predetermined thickness, a circular plate material, other polygonal shapes, non-circular shapes, and the like can be given. Of the four surfaces of the first core described above, when the spacer is disposed in the gap formed between the corner portion formed by two adjacent surfaces and the vicinity thereof and the inner peripheral surface of the winding portion, the plate material such as the rectangular shape is used. A plurality of spacers may be arranged in the gap formed in the corner and the vicinity thereof, or a spacer having a shape suitable for the gap formed in the corner and the vicinity thereof, specifically, two orthogonal pieces are integrally formed. A molded spacer may be used. In particular, when the spacer is made of a rectangular plate material, it is easy to manufacture because of its simple shape, and productivity is good and preferable. In addition, the manufacturing cost of the spacer can be greatly reduced. Specifically, it can be reduced to about several tenths compared with the manufacturing cost of the conventional bobbin.

Such a spacer is preferably formed of an insulating material that also serves as an insulation between the core and the coil. Moreover, it is preferable that the spacer has non-magnetism like the core material. The spacer formed of such a material has an elastic deformability (softness) that can close a gap created between the outer peripheral surface of the core and the inner peripheral surface of the coil winding portion. Those are preferred. Specifically, the elastic modulus is preferably several MPa or more. In addition, the spacer preferably has a heat resistance of 150 ° C. or higher. In order to form such a spacer, a resin such as a thermosetting resin or a thermoplastic resin may be used, and specifically, a urethane resin, an epoxy resin, a PPS resin, or the like may be used. As these resins, a two-component mixed type for casting may be used. In addition to having the above characteristics, the spacer may be formed of the same kind of material as the sealing material described later. In this case, since the familiarity between the spacer and the sealing material is good, when the sealing material is filled, the sealing material is also applied to the exposed portion of the core that is covered with the coil winding portion that is not covered with the spacer. Is easy to flow, and the core and the sealing material are easily in contact with each other. Note that the same type of material as the sealing material means that the base resin used for the spacer contains a material having the same composition as the resin contained in the sealing material.

  The spacer is attached to the coil in advance, and then the core is accommodated in the coil with the spacer between the outer peripheral surface of the core and the inner peripheral surface of the coil winding portion. A spacer may be provided in the created gap, but it may be difficult to attach the spacer to the inner peripheral surface of the cylindrical winding part depending on the size of the coil. In addition, when the coil is formed with the coated conductor, the coating may be peeled off when the spacer is attached to the coil. Therefore, the spacer is preferably attached to the outer peripheral surface of the core. When the spacer is attached, the outer peripheral surface of the core covered with the coil is exposed, so that the spacer can be easily attached and the workability is excellent. Then, by storing the core having the spacer in the coil winding portion, the spacer can be provided in the gap formed between the outer peripheral surface of the core and the inner peripheral surface of the coil winding portion. it can.

  In order to attach the spacer to the coil or the core, for example, an adhesive may be used. In addition, when the spacer is attached to the core, a recess in which the spacer can be disposed may be provided in the core in advance, and the spacer may be attached to the core by fitting the spacer into the recess. At this time, the spacer has a thickness corresponding to the recess and a thickness required for positioning, and when the spacer is arranged in the recess, a part of the spacer protrudes from the core, This protruding portion is used for positioning. In this case as well, an adhesive may be used, but it may be attached to the core by the elasticity of the spacer itself without using an adhesive. The core is previously provided with a recess into which a spacer can be fitted. A core having a dent can be obtained, for example, by using a mold that is provided with a dent as a mold used for molding the core. The recess may have a shape that matches the shape of the spacer, or may not necessarily match the shape of the spacer as long as the spacer can be disposed. For example, when the spacer is a rectangular plate, the core may be provided with a rectangular recess suitable for the plate, or may be provided with a rectangular recess larger than the plate. In the former case, since the dent fits with the spacer, the spacer is difficult to drop off from the core. In the latter case, the dent is large, so the spacer is easy to place.

  After the core / coil combination including the spacer is housed in the case, the case is filled with a sealing material, and is used as a reactor in a state of being sealed in the case by the sealing material. By filling the sealing material, vibrations of the core and the like are suppressed from being transmitted to the case during excitation, and a soundproof function is achieved and rusting of the core and the coil is prevented. In particular, in the present invention, as described above, a part of the outer peripheral surface of the core covered with the coil is not covered with the spacer, and thus can sufficiently contact the sealing material. This sealing material is preferably excellent in sound absorption, but in addition, it is also preferable that it is excellent in thermal conductivity, impact resistance, and electrical insulation. Examples of such a sealing material include resin materials such as urethane resin and epoxy resin. More specifically, a two-component mixed type for casting can be used. More specifically, when the sealing material and the spacer are formed of the same material, the following combinations are preferable. (Sealing material, spacer) = (urethane resin, urethane resin), (epoxy resin, epoxy resin).

The reactor described above can be typically manufactured by the following steps.
I. The process of preparing the core
II. A process in which a spacer for positioning the core and the coil is attached to a part of the outer peripheral surface of the core covered by the coil winding part, and the spacer is not disposed in the remaining part of the part.
III. The process of arranging the coil on the outer periphery of the core with the spacer attached
IV. The process of storing the core including the coil in the case
V. Process of filling the above case with sealing material

  As described above, by attaching the spacer to the core, the spacer can be easily attached, and the productivity of the reactor is excellent. Note that the coil is wound in advance, and a combination of the core and the coil is formed by the step III. When forming this combination, the coil may be fixed and the core may be inserted into the coil winding part, or the core may be fixed and the coil winding part may be fitted into the core. .

  In the reactor of the present invention having the above-described configuration and the reactor obtained by the manufacturing method of the present invention, the relative positioning between the core and the coil is sufficiently performed, and the sealing material can be sufficiently brought into contact with the core. In addition, the rust prevention and noise prevention of the coil and core are more reliably realized. Further, the spacer provided in the reactor of the present invention can have a simple shape and is excellent in productivity and economy. Furthermore, by forming the spacer provided in the reactor of the present invention from the same kind of material as the sealing material, the filling property of the sealing material is excellent, and the productivity of the reactor is excellent. In addition, the manufacturing method of the present invention can easily manufacture such a reactor.

(Example 1)
Hereinafter, embodiments of the present invention will be described with reference to FIGS. FIG. 1 is a perspective view showing a combined body of a coil and a core in the reactor of the present invention, and FIGS. 2 and 3 are explanatory views showing a manufacturing procedure of the reactor of the present invention. In FIG. 1, a part of the coil is cut away. 1 to 3 and FIG. 4 to be described later, the side on which the end portion 23 of the coil 20 is disposed is the upper side. Here, description will be made by taking as an example the reactor used in the converter unit for the hybrid vehicle shown in FIG.

  The reactor includes a core 10 and a coil 20 that is formed by winding a conductive wire and is disposed on the outer periphery of the core 10. The combination of the core 10 and the coil 20 is housed in a case 30 (see FIG. 3), and the case 30 is filled with a sealing material 40 (same as above). This reactor is characterized by the relative positioning of the core 10 and the coil 20 in a part of the gap created between the outer peripheral surface of the core 10 and the inner peripheral surface of the winding part 22 of the coil 20. The point is to have spacer 1 to perform. That is, among the portions of the outer peripheral surface of the core 10 that are covered with the winding portion 22 of the coil 20, there is a portion that is not covered with the spacer 1 and is exposed to the inner peripheral space of the winding portion 22.

  In this example, the core 10 is a member made of a magnetic material (here, silicon steel), and is an annular member made up of a pair of square columnar first cores 11 and a pair of U-shaped columnar second cores 12. is there. As shown in FIG. 2 (a), the first core 11 is formed by combining four block pieces 11a, joining the two block pieces 11a with an adhesive, and insulating material (here ceramic) between the joint pieces 11b. A gap material 11c made of

  A total of four spacers 1 on each of the four surfaces (two pairs of opposing surfaces, the upper and lower surfaces and the left and right surfaces in FIG. 2 (b)) covered with the coil 20 on the outer peripheral surface of each first core 11. (See Fig. 2 (b)). Each spacer 1 is a rectangular plate made of urethane resin, and the size (area in contact with the core 11) is smaller than the area of each surface of the first core 11 on which the spacer 1 is disposed, The entire surface is not covered with the four spacers 1. That is, a part where the spacer 1 is not arranged exists in a part of the four surfaces of the first core 11. In this example, the size of the spacer 1 is such that the spacer 1 is disposed only at the center of each of the four surfaces. The spacer 1 has a thickness sufficient to close the gap formed between the core 10 and the coil 20. The spacer 1 is attached to the first core 11 with an adhesive.

  As shown in FIG. 2 (c), the coil 20 is obtained by winding a tape-shaped conducting wire (flat conducting wire) 21 edgewise. In this example, a series of long conducting wires 21 are wound to form two winding portions 22, and the first core 11 is disposed in a cylindrical space formed by each winding portion 22. In this example, the conducting wire 21 is a copper wire with enamel coating.

  The first core 11 on which the spacer 1 is mounted is disposed on each winding part 22. In this example, as shown by the arrow in FIG. 2 (c), the first core 11 is inserted into the winding part 22, thereby producing a built-in body in which the core 11 is built in the winding part 22. As shown in FIG. 2 (d), the obtained built-in body is provided with spacers 1 in the vertical direction and the horizontal direction, so that a part of the gap created between the core 10 and the coil 20 is formed by the spacer 1. The core 10 is positioned with respect to the coil 20, and the position of the core 10 is stabilized. In this state, the core 10 does not move unnecessarily in the coil 20 and the core 10 does not fall out of the coil 20.

  In the built-in body, the second core 12 is arranged on the end surface of the first core 11 exposed from the opening of the coil 20 (the surface where the gap member 11c is visible in FIG. As shown in FIG. 1, the core 10 and the coil 20 in which the outer peripheral surface of the first core 11 is covered with the winding part 22 of the coil 20 and the outer peripheral surface of the second core 12 is exposed. Get a combination of This combination is stored in the case 30 (see FIG. 3 (e)). The case 30 used in the present example has a rectangular parallelepiped shape with a bottom and an open top, and is made of aluminum.

  The case 30 containing the combination is filled with a sealing material (urethane resin in this example) 40, and the combination is sealed in the case 30 (see FIG. 3 (f)). Sealing was performed so that the entire combination was buried in the sealing material 40 except for the end portion 23 of the coil 20 and the vicinity thereof. In the above combination, a gap is appropriately secured between the core 10 and the coil 20, so that the sealing material 40 can be sufficiently distributed in a relatively short time, and the core 10 and the sealing material 40 Sufficient contact can be ensured. In this example, since the spacer 1 and the sealing material 40 are made of the same material, the familiarity between the spacer 1 and the sealing material 40 is good, and the presence of the spacer 1 makes it difficult to fill the sealing material 40. Can also be prevented.

  Since the obtained reactor is sufficiently filled with the sealing material, rust prevention of the coil 20 and the core 10 and noise prevention due to vibration can be more reliably performed. Further, the reactor can be manufactured relatively easily as described above, and is excellent in productivity. In particular, in this example, since the spacer is attached to the core, the spacer can be easily attached as compared with the case where the spacer is attached to the coil.

(Other examples)
In the first embodiment, a rectangular plate material is used as the spacer. However, as shown in FIG. 4 (e), a disk-shaped plate material may be used. Moreover, although the material of the spacer is the same as that of the sealing material, a different material may be used. In that case, for example, the spacer may be formed of PPS resin and the sealing material may be formed of epoxy resin or urethane resin. Furthermore, in Example 1, the spacers are arranged on the four surfaces of the first core.However, when the spacers are stored in the case, they are arranged in a lower part (FIG. 4 (a)), FIG. 3 (b), (c ) As shown in FIG. 4 (d), or on two opposite surfaces (two surfaces in the vertical direction in FIG. 4 (b) and two surfaces in the left / right direction in FIG. 4 (c)). You may arrange | position in the corner | angular part of four sides.

  In Example 1 above, the spacer is attached to the surface of the first core with an adhesive, and the spacer is attached.As shown in FIG.5 (a), as the first core 11, Prepare one having a rectangular recess 11d that matches the shape of the spacer 2, fit the spacer 2 into this recess 11d, and a part of the spacer 2 protrudes from the first core 11 as shown in FIG. In this way, the spacer 2 may be attached. In this case, the spacer 2 is formed so as to have a thickness that fits into the recess 11d and a thickness that is necessary to close a gap created between the core 10 and the coil 20. In addition, an adhesive may be used for mounting the spacer 2, but the adhesive may not be used as long as the spacer 2 does not fall off the core 10 due to the elasticity of the spacer 2.

  The reactor of the present invention can be used as a reactor that is expected to suppress noise due to vibrations of the core and the like, particularly as a reactor in a converter section of a hybrid vehicle. Moreover, the manufacturing method of this invention reactor can be utilized for manufacture of the said invention reactor.

It is a perspective view which shows the outline of the combination body of a coil and a core in this invention reactor, and cuts and shows a part of coil. FIG. 5 is an explanatory diagram for explaining a manufacturing procedure of the reactor of the present invention, where (a) shows a state of assembling the core, (b) shows a state in which a spacer is arranged on the core, and (c) shows a winding of the coil. The state which inserts a core in a part is shown, (d) is a front view which shows the state which accommodated the core in the winding part of the coil. It is an explanatory view explaining the manufacturing procedure of the reactor of the present invention, (e) shows a state in which a combination of a core and a coil is housed in a case, (f) shows a state in which the case is filled with a sealing material. Show. (a)-(d) is a front view which shows the example of arrangement | positioning of the spacer in this invention reactor, (e) is a perspective view which shows another example of a spacer. (a) is explanatory drawing explaining the state which arrange | positions a spacer in the core which has a dent in this invention reactor, (b) is sectional drawing which shows the state which has arrange | positioned the spacer to this core. It is a schematic circuit diagram which shows the power supply system of a hybrid vehicle. It is a perspective view which shows the outline of the conventional reactor. It is explanatory drawing explaining the manufacturing procedure of the conventional reactor.

Explanation of symbols

1,2 Spacer
10 core 11 first core 11a block piece 11b joint piece 11c gap material
11d dent 12 second core
20 Coil 21 Conductor 22 Winding part 23 End part 30 Case 40 Sealing material
110 Battery 120 Inverter 130 Three-phase AC motor
121 Converter 121A Amplifier 121B Reactor 122 Inverter
100 core 101 first core 102 second core 110 bobbin
110a, 110b Split piece 200 Coil 300 Case

Claims (8)

A reactor including a core and a coil disposed on the outer periphery of the core, these being housed in a case and sealed with a sealing material,
Used in the converter of automobiles,
Some of the gap created between the inner circumferential surface of the winding portion of the coil and the outer peripheral surface of the core, spacer performing relative positioning between the core and the coil is disposed, wherein the remainder There is no spacer,
The said spacer is arrange | positioned in the location located below, when a core and a coil are accommodated in a case, The reactor characterized by the above-mentioned. The core is configured in an annular shape by combining a pair of square columnar first cores and a pair of U-shaped columnar second cores,
The coil is disposed on an outer periphery of the first core;
The spacer, among the tetrahedral covered by the windings of the coil in the outer peripheral surface of the first core, characterized in that disposed in the gap created between the three sides or four sides and the wound portion inner peripheral surface of the The reactor according to claim 1 . The core is configured in an annular shape by combining a pair of square columnar first cores and a pair of U-shaped columnar second cores,
The coil is disposed on an outer periphery of the first core;
The spacer is formed on the outer peripheral surface of the first core between four corners covered by the coil winding portion and between the corner portion formed by two adjacent surfaces and the vicinity thereof and the inner peripheral surface of the winding portion. 2. The reactor according to claim 1 , wherein the reactor is arranged in a gap and a gap formed between the corner portion diagonal to the corner portion and the vicinity thereof and the inner peripheral surface of the winding portion. . The spacer is disposed in a gap formed between four corners and the vicinity thereof and the inner peripheral surface of the winding portion among the four surfaces covered with the winding portion of the coil on the outer peripheral surface of the first core. The reactor according to claim 3, wherein: The core has a dent at a location where the spacer is disposed,
The reactor according to any one of claims 1 to 4, wherein the spacer is attached to the core by fitting the spacer into the recess.   6. The reactor according to any one of claims 1 to 5, wherein the spacer is made of the same material as the sealing material. The reactor according to any one of claims 1 to 6, wherein the spacer is made of a rectangular plate material. A reactor manufacturing method comprising: an arrangement step of arranging a coil on an outer periphery of a core; a housing step of housing a core having the coil in a case; and a sealing step of filling the case with a sealing material. ,
The reactor is used in a converter part of an automobile,
Before the placement step,
A spacer that performs relative positioning of the core and the coil is attached to a portion that is positioned below when the core and the coil are housed in the case among the portions that are covered by the coil winding portion on the outer peripheral surface of the core. The manufacturing method of the reactor characterized by providing the process which does not attach a spacer to remainder.

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