JP5023593B2 - Reactor - Google Patents

Description

  The present invention relates to a reactor mounted on an electric vehicle such as a hybrid vehicle or a fuel cell vehicle.

  In recent years, automobiles that run by driving a motor with a DC power source such as a hybrid vehicle and a fuel cell vehicle have been developed due to environmental problems. The automobile as described above is equipped with a boost converter that boosts the voltage of a battery that is a DC power source, and a reactor is a main component of the boost converter.

  The reactor is configured by attaching a coil to an outer periphery of an annular core via a bobbin that is an insulating member. For example, as described in Patent Document 1, the core is configured by annularly assembling a plurality of blocks, and a spacer formed of a nonmagnetic material is inserted between the blocks. .

  The spacer is a component for adjusting the inductance according to the frequency, and the total thickness of the gaps of the entire core, that is, the total spacer thickness is set to a predetermined dimension.

JP2003-1224039

  An automobile reactor is configured to be able to supply optimum power between a battery and a motor by appropriately controlling a switching circuit.

  However, the core may periodically contract due to repeated on-off of the switching circuit, and noise may be generated. In particular, noise often occurs due to the displacement of the gaps set between the blocks. In order to alleviate the above problem, it is preferable to provide a hard ceramic spacer formed by sintering alumina or the like in the gap so as to prevent displacement of the facing surface.

  However, hard ceramic spacers are expensive. For this reason, if it sets so that the said clearance gap may be filled up as it describes in patent document 1, a manufacturing cost will increase. In addition, the spacer and the core are often joined by a heat-resistant adhesive. However, if the spacer is set so as to fill the entire gap, the amount of the adhesive used increases, which increases the manufacturing cost. Moreover, workability in the bonding process is also poor.

  The present invention provides a reactor that can reduce the manufacturing cost without deteriorating noise characteristics and the like, and can further improve the assembly workability.

The present invention includes an annular core configured by assembling a plurality of blocks formed using magnetic powder, a spacer for setting a predetermined gap between the blocks, and a coil provided on the outer periphery of the core. And a bobbin disposed on the outer periphery of the annular core, wherein each block is disposed in a part of each gap and is held via a spacer formed of the same form and the same material In addition, the bobbin is provided with an extending portion that extends into the gap, and the spacers that are brought into contact with the opposing surfaces of adjacent blocks are positioned and held via the extending portion.

In the present invention, the annular core is configured by assembling a plurality of blocks formed using magnetic powder. By adopting a block formed by compacting magnetic powder, the manufacturing cost can be reduced as compared with a conventional core made of laminated steel sheets. Moreover, compared with the core which consists of a conventional laminated steel plate, freedom, such as a shape, is high. For this reason, a reactor can be manufactured according to the required dimensional shape and the like. In addition, the core can also be formed by mixing blocks formed by compacting magnetic powder and blocks made of laminated steel sheets.

Each said block is arrange | positioned in a part of each clearance gap, and is hold | maintained via the spacer formed with the same form and the same material. That is, as described in Patent Document 1, the entire gap is not filled with spacers, but the spacers are arranged within a range in which a predetermined gap can be secured between the blocks and vibration characteristics are not deteriorated. Has been.

  The material of the spacer is not particularly limited. For example, it can be formed by sintering ceramic powder such as alumina which is a non-magnetic material.

Also, the form of the spacer is not particularly limited. Various types of spacers such as a rectangular plate shape and a circular plate shape can be employed. Moreover, it is not limited to plate shape, A spherical spacer can also be employ | adopted. Further, the number of the spacers is not limited. For example, a plurality of spacers can be arranged at predetermined intervals in the vicinity of the center part or the edge part of the opposing surface.

  By adopting the above configuration, the material required for manufacturing the spacer is reduced, and the manufacturing cost can be reduced. Moreover, since the adhesion surface with respect to the block of a spacer decreases, the usage-amount of an adhesive agent also decreases. Therefore, it becomes possible to reduce the manufacturing cost of the reactor.

  When a plurality of spacers are provided in a part of the gap between the blocks, it is preferable to position these at predetermined positions on the assembly facing surface.

The present invention includes a bobbin disposed on the outer peripheral portion of the annular core, and positions and holds the spacer that is brought into contact with the opposing surface of an adjacent block through the bobbin.

Since the bobbin is formed by resin molding, the design freedom is high. In addition, the manufacturing cost is lower than that of the core or spacer. The present invention is configured to hold the spacer abutted against the opposing surface of the adjacent block at a predetermined position by using the bobbin.

In the present invention, the bobbin is provided with an extending portion that extends into the gap in which the spacer is inserted, and the spacer is positioned and held via the extending portion. For example, when a disc-shaped spacer is disposed at the center of the assembly facing surface, an extension portion that contacts the peripheral edge of the disc and can position the disk-shaped spacer at the center of the assembly facing surface is provided. Can be provided. Since the spacer can be held at a predetermined position using the bobbin, an adhesive is not necessary, and the manufacturing cost can be reduced.

Note that the extending portion need not be integrally formed with the bobbin. A positioning member for connecting and positioning the bobbin and the spacer may be provided as the extending portion.

  FIG. 1 shows an external view in which a part is broken so that the internal structure of the reactor can be understood. The reactor 1 includes a core 2, a coil 3 wound around the core 2 in an annular shape, a bobbin 4 interposed between the core 2 and the coil 3, and a case 5 for housing these members. It is configured with.

  As shown in FIG. 2, the core 2 is formed by assembling a plurality of blocks formed using magnetic powder. In the embodiment, a rectangular parallelepiped block 6a disposed in the longitudinal linear portion of the core 2 and a C-shaped block 6b in plan view disposed at both ends in the longitudinal direction are assembled into a track shape. Yes. Spacers 7 a are arranged between the blocks, and the blocks 6 a and 6 b are assembled with a predetermined gap 9. The spacer 7a can be formed by sintering a nonmagnetic material such as alumina powder.

FIG. 3 shows an embodiment of the present invention. In this embodiment, an extension portion 13 is provided on the inner peripheral portion of the bobbin 4 so as to extend into the gap 9 between the mounting facing surfaces of the block 6, and the spacer 7 g disposed in the gap 9 is arranged at the center portion of the gap 9. It is configured so that it can be positioned and held .

By adopting the above configuration , the spacer 7g can be held without using an adhesive, and the manufacturing cost can be reduced.

In the above embodiment , the bobbins are provided with the extending portions, but these extending portions can be formed by separate members. In particular, each spacer can be positioned and held at a predetermined position, and an assembly member capable of integrally assembling a plurality of spacers is provided, and the assembly workability can be improved by positioning the assembly member with a bobbin. .

It is the whole reactor perspective view which fractured | ruptured and represented the internal structure. It is a disassembled perspective view which shows the assembly structure of a spacer. It is sectional drawing which shows the assembly | attachment state of the spacer which concerns on an Example.

2 core 6a block 6b block 7a spacer 7f spacer 7g spacer 9 gap

Claims (1)

An annular core formed by assembling a plurality of blocks formed using magnetic powder, a spacer for setting a predetermined gap between the blocks, a coil provided on the outer periphery of the core, and the annular core A reactor provided with a bobbin disposed on the outer periphery of the
Each of the above blocks is arranged in a part of each gap and is held via a spacer formed of the same form and the same material,
The reactor which provided the extension part extended in the said clearance gap to the said bobbin, and positioned and hold | maintained each said spacer contacted to the opposing surface of the adjacent block via the said extension part.

Images