JP6519741B2 - Reactor, converter, and power converter - Google Patents

Description

  The present invention relates to a reactor used as a component of an on-vehicle DC-DC converter or a power conversion device mounted on an electric vehicle such as a hybrid vehicle, a converter using the reactor, and a power conversion device using the converter.

  Magnetic components including a coil having a winding portion formed by winding a winding, such as a reactor or a motor, and a magnetic core partially inserted into the winding portion are used in various fields. . As such a magnetic component, there can be mentioned a reactor including a coil having a winding portion formed by winding a winding, and a magnetic core partially inserted into the winding portion (for example, a patent) Reference 1).

  The magnetic core with which the reactor is provided is configured by combining a plurality of divided cores (referred to as core parts in Patent Document 1). Examples of the divided core include a green compact obtained by pressure molding soft magnetic powder, a composite material in which soft magnetic powder is contained in a resin, and a laminate in which electromagnetic steel sheets are laminated. In particular, since the composite material can set the mixing ratio of the soft magnetic powder to the resin in a wide range, it is considered that it is easy to manufacture a split core satisfying the relative permeability required for the magnetic component.

  The split core made of a composite material is mainly produced by mixing a soft magnetic powder with a thermoplastic resin or a thermosetting resin and injecting the mixture into a mold. In such injection molding, the mold is cooled or heated to cure the resin and complete the split core. However, when the resin cures, the outer portion of the split core in contact with the mold cures faster than the inner portion of the split core, so that the air bubbles contained in the mixture are contained in the split core. It is contained and it is easy to form a void inside the split core. Since the voids destabilize the magnetic properties of the split core depending on the size thereof, there is a need to suppress the formation of voids inside the split core. With respect to such a problem, in Patent Document 1, it is made difficult to form a void in the inside of the split core by reducing the thickness of the split core.

JP, 2014-139988, A

  The reactor described in Patent Document 1 has room for improvement in terms of its productivity.

  In patent document 1, the inner core part arrange | positioned inside the winding part of a coil among magnetic cores is comprised combining a some split core. And the outer core part is arrange | positioned on both the end surfaces of the inner core part on both sides of an insulation interposition member (it is described as a bobbin in patent document 1). As described above, the configuration of Patent Document 1 has a problem that the number of divisions of the magnetic core is large. When the number of divisions is large, a mold corresponding to each divided core is required, and the step of combining the divided cores also increases. Moreover, when combining these divided cores, the positioning of each divided core becomes complicated, and the conventional reactor has room for improvement in terms of productivity.

  The present invention has been made in view of the above-described circumstances, and one of the objects thereof is to provide a reactor having a magnetic core composed of a composite material and having excellent productivity. Another object of the present invention is to provide a converter using a reactor and a power converter using the converter.

A reactor according to one aspect of the present invention is a reactor including a coil having a winding portion and a magnetic core having an inner core portion disposed inside the winding portion, wherein at least one of the magnetic cores is provided. The part is formed by combining a first divided core and a second divided core which are composed of a composite material in which a soft magnetic powder is contained in a resin.
The first divided core is integrally provided on a first outer core portion disposed on the outer side of the winding portion on one end side in the axial direction of the winding portion, and the first outer core portion, And a first insertion part inserted into the winding part from one end face of the part.
The second divided core is integrally provided on a second outer core portion disposed outside the winding portion on the other end side in the axial direction of the winding portion, and the second outer core portion, And a second insertion portion inserted from the other end surface of the winding portion into the inside of the winding portion.
In the reactor having the above configuration, the first insertion portion and the second insertion portion are arranged in the direction crossing the axial direction of the winding portion inside the winding portion, so that the reactor is disposed inside the winding portion. The inner core portion is formed. Further, in the reactor having the above configuration, on the end face side of any one of the winding parts, a separation part is formed in which the first divided core and the second divided core are separated in the axial direction of the winding part. .

  The reactor is excellent in productivity.

1 is a schematic perspective view of a reactor according to Embodiment 1. FIG. 1 is a horizontal cross-sectional view of a reactor according to Embodiment 1. FIG. FIG. 6 is a horizontal cross-sectional view of a reactor according to Embodiment 2. FIG. 7 is a horizontal cross-sectional view of a reactor according to a third embodiment. FIG. 10 is a horizontal cross-sectional view of a reactor according to a fourth embodiment. It is a longitudinal cross-sectional view of the reactor which concerns on Embodiment 5. FIG. The upper part is a schematic view of the reactor according to the seventh embodiment, and the lower part is a longitudinal sectional view of the reactor. FIG. 1 is a schematic configuration view schematically showing a power supply system of a hybrid vehicle. It is a general | schematic circuit which shows an example of a power converter device provided with a converter.

Description of the embodiment of the present invention
First, the embodiments of the present invention will be listed and described.

<1> The reactor according to the embodiment is a reactor including a coil having a winding portion and a magnetic core having an inner core portion disposed inside the winding portion, and at least one of the magnetic cores The part is formed by combining a first divided core and a second divided core which are composed of a composite material in which a soft magnetic powder is contained in a resin.
The first divided core is integrally provided on a first outer core portion disposed on the outer side of the winding portion on one end side in the axial direction of the winding portion, and the first outer core portion, And a first insertion part inserted into the winding part from one end face of the part.
The second divided core is integrally provided on a second outer core portion disposed outside the winding portion on the other end side in the axial direction of the winding portion, and the second outer core portion, And a second insertion portion inserted from the other end surface of the winding portion into the inside of the winding portion.
In the reactor having the above configuration, the first insertion portion and the second insertion portion are arranged in the direction intersecting the axial direction of the winding portion inside the winding portion, so that the inside of the winding portion is formed. The inner core portion to be disposed is formed. Further, in the reactor having the above configuration, on the end face side of any one of the winding parts, a separation part is formed in which the first divided core and the second divided core are separated in the axial direction of the winding part. .

  The said reactor is excellent in productivity. While inserting the first insertion portion of the first divided core from one end side of the winding portion in the axial direction, the second insertion portion of the second divided core is inserted from the other end side of the winding portion in the axial direction. This is because the first outer core portion, the second outer core portion, and the inner core portion can be assembled to the winding portion only by connecting the split cores.

  Moreover, according to the said structure, it can be set as the reactor provided with the stable magnetic characteristic. The inner core portion disposed inside the winding portion has a form in which a void is less likely to be formed therein, and thus the disturbance of the magnetic characteristics due to the void is less likely to occur. As defined in the above <1>, the inner core portion is configured of a first insertion portion and a second insertion portion aligned in a direction intersecting the axial direction of the winding portion. That is, both insertion parts are thinner than producing an inner core part as one. If the insertion portion has a small thickness, air bubbles are easily expelled from the inside of the insertion portion when curing the resin constituting the insertion portion, and therefore, it is difficult to form a void inside the insertion portion.

  Furthermore, according to the above configuration, the reactor can be provided with magnetic characteristics according to the application. This is because the separation part formed by separating the first divided core and the second divided core in the axial direction of the winding part functions as a gap for adjusting the overall magnetic characteristics of the magnetic core. That is, if the size of the separation portion functioning as the gap is adjusted, it is possible to obtain a reactor having desired magnetic characteristics.

As a reactor of <2> embodiment, a pair of the said winding part is provided and both winding parts are paralleled so that the axial direction of one winding part and the axial direction of the other winding part may become mutually parallel, The first split core includes the first insertion portion inserted into each of the one winding portion and the other winding portion, and the second split core includes the one winding portion and the other. In the embodiment, the second insertion portion may be inserted into each of the winding portions. In this case, the separation portion formed on the side of the one winding portion is disposed on one of the end surface side and the other end surface side of the one winding portion, and the separation portion is formed on the other winding portion. The said separation part formed in the side is arrange | positioned on the opposite side to the said separation part in the said one winding part among the one end surface side and other end surface side of the said other winding part.

  According to the above configuration, as shown in Embodiment 1 to be described later, it is possible to complete the magnetic core connected in an annular shape only by combining the first divided core and the second divided core. In addition, one of the separation portions formed on the side of one winding portion and the other separation portion formed on the side of the other winding portion are point symmetrical with respect to the center of the annular magnetic core. The coil loss can be reduced by being disposed at If one separation part generating leakage flux and the other separation part are disposed on the same side in the axial direction of the winding part, there is a possibility that the loss accompanying the increase of the leakage magnetic flux crossing the coil may become large.

<3> As a reactor of the embodiment including one winding portion and the other winding portion arranged in parallel, the first insertion portion and the second insertion portion are formed inside the one winding portion and the other winding portion. There can be mentioned a form in which the two insertion parts are arranged in the parallel direction of both winding parts.

  As shown in FIGS. 2 to 5 of the embodiment to be described later, the configuration in which the first insertion portion and the second insertion portion are arranged in the parallel direction of the pair of winding portions produces the first divided core and the second divided core. Easy to do. In addition, since the size of the separation portion easily affects the magnetic characteristics, it is easy to obtain the target magnetic characteristics by adjusting the size of the separation portion.

When one of the first insertion portion and the second insertion portion is an insertion portion X and the other is an insertion portion Y as a reactor in the <4> embodiment, it is one of the side surfaces of the insertion portion X, A part of the distal end side of the insertion part X is tapered so that a part of the distal end side of the insertion part X is separated from the insertion part Y among the opposing surfaces facing the insertion part Y The form can be mentioned.

  According to the above configuration, when the insertion portion X and the insertion portion Y are inserted from both end portions of the winding portion, it is difficult for the ends of both insertion portions to collide with each other. Therefore, both insertion parts are easy to insert and both insertion parts are hard to be damaged. In addition, since a part of the distal end side of the insertion portion X is tapered, a gap is formed in the parallel direction of the insertion portion X and the insertion portion Y on the distal end side of the insertion portion X. This gap contributes to the adjustment of the magnetic properties of the magnetic core. That is, the gap functions as an auxiliary gap that compensates for the gap function of the separation portion. By forming such a gap, it is possible to obtain a magnetic field obtained by increasing the separation distance without widening the distance between the separation parts (the separation distance between the first divided core and the second divided core in the axial direction of the winding part). The adjustment effect of the characteristic can be obtained. If the separation distance is expanded, the leakage magnetic flux tends to increase at the position of the separation part. However, in the configuration in which a gap is provided in the parallel direction of the insertion portion X and the insertion portion Y, the adjustment effect of the magnetic characteristics while suppressing the increase of the leakage magnetic flux You can get

As a reactor of <5> embodiment, the said 1st division | segmentation core and the said 2nd division | segmentation core can mention the form provided with the same shape.

  According to the above configuration, since the first divided core and the second divided core can be manufactured with the mold having the same shape, the productivity of the reactor can be further improved.

As a reactor of <6> embodiment, the said 1st insertion part and the said 2nd insertion part can mention the form which is the tapering shape which becomes thin as the whole goes to a tip side from a root side.

  By forming the insertion portion in a tapered shape as a whole, when the split core including the insertion portion is manufactured, the split core can be easily removed from the mold. In addition, when inserting the first insertion portion of the first divided core from one end face of the winding portion and inserting the second insertion portion of the second divided core from the other end face of the same winding portion, the tips of both insertion portions It is hard to collide with each other. Therefore, both insertion parts are easy to insert and both insertion parts are hard to be damaged.

The converter of <7> embodiment is provided with the reactor of the said embodiment.

  The converter is excellent in magnetic characteristics and productivity. It is because the reactor of the embodiment with which a converter is equipped is excellent in a magnetic characteristic and productivity.

The power converter of <8> embodiment is provided with the converter of the said embodiment.

  The power converter is excellent in magnetic characteristics and productivity. It is because the converter of embodiment provided in a power converter device is excellent in a magnetic characteristic and productivity.

Details of the Embodiment of the Present Invention
Details of embodiments of the present invention are described below. The present invention is not limited to these exemplifications, but is shown by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

First Embodiment
In the first embodiment, referring to FIGS. 1 and 2, a coil 2 having a pair of wound portions 2A and 2B, and an annular magnetic core 3 partially inserted into the wound portions 2A and 2B. The description will be made by taking the reactor 1 including the above as an example. The reactor 1 further includes an insulation interposition member 4 that ensures insulation between the coil 2 and the magnetic core 3. The main difference between this reactor 1 and the conventional reactor 1 is in the divided shape of the magnetic core 3. Hereinafter, prior to the description of the divided shape of the magnetic core 3, an outline of each configuration 2, 3, and 4 of the reactor 1 will be described. Thereafter, the divided shape of the magnetic core 3 will be described in detail.

[coil]
The coil 2 includes a pair of winding parts 2A and 2B and a connecting part 2r connecting the two winding parts 2A and 2B. The respective winding portions 2A and 2B are formed in a hollow cylindrical shape with the same number of turns and the same winding direction, and are arranged side by side so that the respective axial directions are parallel. The connecting portion 2r is a portion bent in a U-shape connecting the two winding portions 2A and 2B. The coil 2 may be formed by spirally winding a single winding without a joint, or each winding 2A, 2B is manufactured by separate windings, and each winding 2A, 2B is You may form by joining the ends of a winding by soldering or pressure bonding.

  The coil 2 can suitably utilize a coated wire provided with an insulating coating made of an insulating material on the outer periphery of a conductor such as a rectangular wire or a round wire made of a conductive material such as copper, aluminum, or an alloy thereof. In this embodiment, the conductor is a flat wire made of copper, and the insulating coating is a coated flat wire made of enamel (typically polyamideimide), and each wound portion 2A, 2B is edgewise coated with the coated flat wire. It is an edgewise coil wound. Further, although the end face of each winding portion 2A, 2B is formed by rounding the corner of a rectangle, the end face can be changed as appropriate, such as circular.

  Both end portions 2a and 2b of the coil 2 are extended from the turn forming portion, and the coating is peeled off and connected to a terminal member (not shown). An external device (not shown) such as a power supply for supplying power to the coil 2 is connected via the terminal member.

[Magnetic core]
For convenience, as shown in the horizontal sectional view of FIG. 2, the magnetic core 3 in the present embodiment includes an inner core portion 3A, an inner core portion 3B, a first outer core portion 3C, and a second outer core portion 3D. It can be divided. The inner core portion 3A and the inner core portion 3B are portions disposed inside the winding portion 2A and the winding portion 2B, respectively, and are portions having an axial direction along the axial direction of the winding portions 2A and 2B. (See the part sandwiched by the two-dot chain line). In the case of this example, the inner core portions 3A and 3B are formed in a substantially columnar shape, and the portions projecting from the end faces of the winding portions 2A and 2B are also a part of the inner core portions 3A and 3B. On the other hand, the first outer core portion 3C is a portion connecting one axial end face (surface on the left side in the drawing) of the inner core portions 3A, 3B, and the second outer core portion 3D is an axis of the inner core portions 3A, 3B. It is a part which connects the other end face of the direction (the surface on the right side of the drawing).

  The magnetic core 3 is made of a composite material in which a soft magnetic powder is contained in a resin. Iron, an iron-based alloy, an alloy containing a rare earth element, or the like can be used as the soft magnetic powder contained in the composite material. Moreover, coating powder provided with insulation coating on the surface of soft magnetic particles can also be used as soft magnetic powder.

  On the other hand, a thermoplastic resin or a thermosetting resin can be mentioned as resin used for a composite material. Examples of the thermoplastic resin include polyphenylene sulfide (PPS) resin, a part of polyimide resin, and fluorine resin. On the other hand, as the thermosetting resin, for example, epoxy resin, phenol resin, silicone resin, urethane resin, some polyimide resin, BMC (Bulk molding compound) mixed with calcium carbonate and glass fiber, and the like can be mentioned. .

  In addition, the composite material may contain a ceramic filler. The ceramic filler may include at least one selected from silicon nitride, alumina, aluminum nitride, boron nitride, mullite, and silicon carbide. The ceramic filler contributes to the improvement of the heat dissipation of the composite material and the suppression (uniform distribution) of the uneven distribution of the soft magnetic powder in the composite material.

  The content of the soft magnetic powder in the composite material can be appropriately selected depending on the degree to which the magnetic properties (relative magnetic permeability and saturation magnetic flux density) of the magnetic core 3 are to be made. For example, when the composite material is 100%, the content of the soft magnetic powder can be 20% to 85% by volume, or 40% to 65% by volume. Moreover, when making a composite material contain a ceramic filler, the content can be selected suitably. For example, when the composite material is 100% by mass, the content of the filler is 0.2% by mass or more and 20% by mass or less, and further 0.3% by mass or more and 15% by mass or less, particularly 0.5% by mass or more and 10% by mass If it is the following, the effect by a filler is fully acquired.

[Insulation interposition member]
In addition to the coil 2 and the magnetic core 3, the reactor 1 of the present embodiment includes an insulation interposing member 4 that ensures insulation between the coil 2 and the magnetic core 3 (see FIG. 1). More specifically, insulation interposing member 4 secures insulation between the inner peripheral surface of winding portions 2A and 2B of coil 2 and the outer peripheral surface of inner core portions 3A and 3B, and also the winding portion Insulation is secured between the end faces of 2A and 2B and the outer core portions 3C and 3D. Since the configuration of the insulating interposition member 4 is known, the detailed description thereof is omitted. Moreover, in FIGS. 3-7 referred after Embodiment 2 or later demonstrated, illustration of the insulation interposition member 4 is also abbreviate | omitted.

[Divided state of magnetic core]
The division state of the magnetic core 3 of this example will be described based on FIG. As shown in FIG. 2, the magnetic core 3 of the present example is configured by combining a first divided core 31 and a second divided core 32 whose shape viewed from the top is substantially F-shaped. The first split core 31 and the second split core 32 have the same shape (if the first split core 31 is rotated by 180 °, it becomes the second split core 32).

  The first divided core 31 is configured of a first outer core portion 3C and first insertion portions 31a and 31b integrally provided to the first outer core portion 3C. The first insertion portion 31a is inserted into the inside of the winding portion 2A from one end face side (left side in the drawing) of the winding portion 2A. On the other hand, the first insertion portion 31b is inserted into the inside of the winding portion 2B from one end face side (left side in the drawing) of the winding portion 2B.

  The second divided core 32 is configured of a second outer core portion 3D and second insertion portions 32a and 32b integrally provided to the second outer core portion 3D. The second insertion portion 32a is inserted into the inside of the winding portion 2A from the other end surface side (right side in the drawing) of the winding portion 2A. On the other hand, the second insertion portion 32b is inserted into the inside of the winding portion 2B from the other end surface side (right side in the drawing) of the winding portion 2B.

  A portion of the first insertion portion 31a of the first split core 31 and the second insertion portion 32a of the second split core 32 are juxtaposed in a direction intersecting the axial direction of the winding portion 2A inside the winding portion 2A. Ru. That is, the inner core portion 3A is formed by both the insertion portions 31a and 32a. The side surface of the first insertion portion 31 a and the side surface of the second insertion portion 32 a may or may not be in contact with each other. Here, the first insertion portion 31a is longer than the second insertion portion 32a. Therefore, when the front end surface of the first insertion portion 31a is brought into contact with the second outer core portion 3D on the other end surface side (right side in the drawing) of the winding part 2A, on one end surface side (left in the drawing) The first outer core portion 3C and the second insertion portion 32a are separated. The separated space (separation part 3AG) functions as a gap for adjusting the magnetic characteristics of the magnetic core 3.

  On the other hand, a part of the first insertion portion 31b of the first divided core 31 and a part of the second insertion portion 32b of the second divided core 32 cross the axial direction of the winding portion 2B inside the winding portion 2B. Be paralleled. That is, the inner core portion 3B is formed by both the insertion portions 31b and 32b. The side surface of the first insertion portion 31 b and the side surface of the second insertion portion 32 b may or may not be in contact with each other. Here, the second insertion portion 32 b is longer than the first insertion portion 31 b. Therefore, when the front end surface of the second insertion portion 32b is brought into contact with the first outer core portion 3C on one side (left side in the drawing) of the winding portion 2B, on the other end side (right side in the drawing) of the winding portion 2B, The second outer core portion 3D and the first insertion portion 31b are separated. The separated space (separation part 3BG) functions as a gap for adjusting the magnetic characteristics of the magnetic core 3.

  The gap length of the separation parts 3AG and 3BG (the separation distance in the axial direction of the winding parts 2A and 2B) can be selected as appropriate. For example, the gap length is preferably 0.1 mm or more and 5 mm or less, and more preferably 0.5 mm or more and 3 mm or less. By setting the gap length in this range, it is possible to obtain the adjustment effect of the magnetic characteristics of the magnetic core 3 by the separation portions 3AG and 3BG while suppressing the increase of the leakage flux at the positions of the separation portions 3AG and 3BG.

  The positions at which the separation portions 3AG and 3BG are formed are inward in the parallel direction of the winding portions 2A and 2B in the inner core portions 3A and 3B. Therefore, it is difficult for the magnetic flux to leak from the separation parts 3AG and 3BG to the outer side of the reactor 1, and the loss of the coil 2 due to the leakage flux is unlikely to occur. Here, unlike the illustrated example, the positions at which the separation portions 3AG and 3BG are formed may be the outer sides in the parallel direction of the winding portions 2A and 2B. For example, the distal end surface of the second insertion portion 32a (first insertion portion 31b) is brought into contact with the first outer core portion 3C (second outer core portion 3D), and the first insertion portion 31a (second insertion portion 32b) When the front end surface is separated from the second outer core portion 3D (first outer core portion 3C), the separation portion 3AG is provided on the outer side in the parallel direction of the winding portions 2A and 2B in the inner core portion 3A (3B). (3BG) can be formed. Similarly, in the embodiment to be described later, the positions of the separation portions 3AG and 3BG can be arranged on the outer side in the parallel direction of the winding portions 2A and 2B.

  Separation portions 3AG and 3BG formed by separating the first divided core 31 and the second divided core 32 which are magnetic bodies are so-called air gaps. Other configurations excluding the magnetic core 3 and the coil 2 may be disposed in the separation portions 3AG and 3BG. For example, when the reactor 1 is housed in a case and embedded with potting resin, the potting resin enters the separation portions 3AG and 3BG. Further, when the reactor 1 is used in a state of being immersed in the refrigerant, the refrigerant enters the separation portions 3AG and 3BG. Even if the potting resin and the refrigerant enter the separation parts 3AG and 3BG, the parts of the separation parts 3AG and 3BG still function as gaps.

[Summary]
The reactor 1 provided with the magnetic core 3 in the divided state described above is excellent in productivity. The first insertion portions 31a and 31b of the first split core 31 are inserted from one end side in the axial direction of the winding portions 2A and 2B, and the second divided core 32 from the other end side in the axial direction of the winding portions 2A and 2B. The magnetic core 3 can be assembled to the coil 2 simply by inserting the second insertion portions 32a and 32b and connecting the contact portions of the split cores 31 and 32 with an adhesive or the like.

  Moreover, according to the said structure, it can be set as the reactor 1 provided with the stable magnetic characteristic. The inner core portions 3A and 3B disposed inside the winding portions 2A and 2B are in a form in which a void is less likely to be formed therein, and disturbance of the magnetic characteristics due to the void is less likely to occur. The inner core portion 3A (3B) is composed of a first insertion portion 31a (31b) and a second insertion portion 32a (32b) aligned in a direction intersecting the axial direction of the winding portion 2A (2B). That is, both insertion parts 31a and 32a (31b, 32b) are thinner than producing inner core part 3A (3B) as one. In the case of a thin insertion portion 31a, 32a (31b, 32b), when curing the resin constituting the insertion portion 31a, 32a (31b, 32b), air bubbles are generated from the inside of the insertion portion 31a, 32a (31b, 32b) It is easy to get rid of Therefore, it is difficult to form a void inside the insertion portions 31a, 32a (31b, 32b), and the disturbance of the magnetic characteristics due to the void does not easily occur at the position of the inner core portion 3A (3B).

  Furthermore, according to the above configuration, the reactor 1 can be provided with the magnetic characteristics according to the application. This is because it is easy to adjust the overall magnetic characteristics of the magnetic core 3 by the separation portions 3AG and 3BG. In particular, in the present example, the position where the separation portion 3AG formed on the side of the winding portion 2A and the separation portion 3BG formed on the side of the winding portion 2B are point symmetrical with respect to the center of the annular magnetic core 3 Is located in Therefore, since the leakage of the magnetic flux from both separation parts 3AG and 3BG is also separated at the point-symmetrical position, the increase of the leakage flux crossing the coil 2 can be suppressed, and the loss of the coil 2 can be reduced.

Second Embodiment
In the second embodiment, a reactor 1 in which a first insertion portion 31a of a first split core 31 and a second insertion portion 32b of a second split core 32 are formed in a step shape will be described based on FIG.

  The first insertion portion 31a constituting a part of the inner core portion 3A is thicker at its root side and thinner at its distal end than its root portion. Further, the length of the second insertion portion 32a that constitutes the inner core portion 3A together with the first insertion portion 31a is shorter than the length of the thin portion of the first insertion portion 31a. Therefore, the separation portion 3AG is formed between the tip end surface of the second insertion portion 32a and the root portion of the first insertion portion 31a. The separation portion 3AG is in a state of being disposed inside the winding portion 2A.

  The second insertion portion 32b constituting a part of the inner core portion 3B is thicker at its root side and thinner at its tip end than at its root portion. Further, the length of the first insertion portion 31b that constitutes the inner core portion 3B together with the second insertion portion 32b is shorter than the length of the thin portion of the second insertion portion 32b. Therefore, the separation portion 3BG is formed between the distal end surface of the first insertion portion 31b and the root portion of the second insertion portion 32b. The separation portion 3BG is in a state of being disposed inside the winding portion 2B.

  According to the above configuration, since the separation portion 3AG (3BG) is disposed inside the winding portion 2A (2B), it is possible to suppress the leakage of the magnetic flux from the separation portion 3AG (3BG) to the outside of the magnetic core 3 it can.

Embodiment 3
In the third embodiment, the reactor 1 in which the first insertion portions 31a and 31b of the first split core 31 and the second insertion portions 32a and 32b of the second split core 32 both have a tapered shape will be described based on FIG. Do.

  Of the side surfaces of the first insertion portion 31a constituting a part of the inner core portion 3A, the surface on the outer side in the parallel direction of the winding portions 2A and 2B is a plane along the axial direction of the winding portions 2A and 2B. It has become. Of the side surfaces of the first insertion portion 31a, the surface on the inner side in the parallel direction of the winding portions 2A and 2B (opposite surface facing the second insertion portion 32a) has the above-mentioned parallel direction from the root toward the tip. It is an inclined surface that inclines outward. On the other hand, of the side surfaces of the second insertion portion 32a constituting a part of the inner core portion 3A, the surface on the inner side in the parallel direction of the winding portions is a plane along the axial direction of the winding portions 2A and 2B. It has become. Out of the side surfaces of the second insertion portion 32a, the surface on the outer side in the parallel direction of the winding portions 2A and 2B (opposite surface facing the first insertion portion 31a) has the above-mentioned parallel direction from the root toward the tip. It is an inclined surface that inclines inward.

  The first insertion portion 31b constituting a part of the inner core portion 3B has the same shape as that of the second insertion portion 32a in point symmetry. Further, the second insertion portion 32b which constitutes a part of the inner core portion 3B has the same shape as that of the first insertion portion 31a in point symmetry.

  According to the configuration shown in FIG. 4, the first insertion portion 31a (31b) of the first split core 31 is inserted from one end surface of the winding portion 2A (2B) and from the other end surface of the winding portion 2A (2B) When the second insertion portion 32a (32b) of the second split core 32 is inserted, the tips of both the insertion portions 31a and 32a (31b and 32b) hardly collide with each other. Therefore, both the insertion parts 31a and 32a (31b, 32b) are easily inserted, and both the insertion parts 31a and 32a (31b, 32b) are not easily damaged.

Fourth Embodiment
In the first to third embodiments, the configuration in which the inner core portions 3A and 3B are divided into two in the parallel direction of the winding portions 2A and 2B has been described. On the other hand, in the fourth embodiment, a configuration in which the inner core portions 3A and 3B are divided into three in the parallel direction of the winding portions 2A and 2B will be described based on FIG.

  The first split core 31 of the present example includes two first insertion portions 31a and 31a integrated with the first outer core portion 3C and one first insertion portion 31b. In addition, the second divided core 32 of this example includes two second insertion portions 32b and 32b integrated with the second outer core portion 3D and one second insertion portion 32a.

  The distance between the two first insertion portions 31 a and 31 a of the first split core 31 is substantially the same as the thickness of the second insertion portion 32 a of the second split core 32. Similarly, the distance between the two second insertion portions 32 b and 32 b of the second divided core 32 is substantially the same as the thickness of the first insertion portion 31 b of the first divided core 31. Therefore, when the first split core 31 and the second split core 32 are combined, the inner core portion 3A is formed by the two first insertion portions 31a and 31a and one second insertion portion 32a, and The inner core portion 3B is formed by the two second insertion portions 32b and 32b and the one first insertion portion 31b.

  According to the above configuration, the thickness of each of the insertion portions 31a, 31b, 32a, 32b can be thinner than in the first to third embodiments. Therefore, the possibility that a void is formed at the position of the inner core portions 3A and 3B can be made lower than in the first to third embodiments.

Fifth Embodiment
In the fifth embodiment, a configuration in which the inner core portions 3A and 3B are divided in the height direction (vertical direction in the drawing) will be described based on FIG. The top view of FIG. 6 is a longitudinal cross-sectional view of a portion where the winding portion 2A of FIG. 1 is provided, and the lower view of FIG. 6 is a longitudinal cross-sectional view of a portion where the winding portion 2B of FIG.

  The first insertion portion 31a of the first divided core 31 of the present example is disposed on the upper side in the height direction of the reactor 1 as shown in the upper drawing, and the first insertion portion 31b is the above-mentioned high as shown in the lower drawing. It is disposed on the lower side in the longitudinal direction.

  On the other hand, the second insertion portion 32a of the second split core 32 is disposed on the lower side in the height direction of the reactor 1 as shown in the upper diagram, and the second insertion portion 32b has the above height as shown in the lower diagram. It is arranged on the upper side of the direction. The second split core 32 having such a shape and the first split core 31 described above can be manufactured using the same mold.

  According to the above configuration, the separation portion 3AG formed on the side of the winding portion 2A and the separation portion 3BG formed on the side of the winding portion 2B can be brought closer to the lower side in the height direction. In this example, since the outer core parts 3C and 3D protrude downward in the height direction, by arranging the separation parts 3AG and 3BG on the lower side, the magnetic flux is transmitted to the outside of the magnetic core 3 from the separation parts 3AG and 3BG. Is less likely to leak.

Embodiment 6
In the sixth embodiment, a reactor 1 will be described in which the tip end portions of at least one of the first insertion portions 31a and 31b and the second insertion portions 32a and 32b are locally tapered. 2 to 6 will be referred to for the explanation.

  One of the first insertion portion 31a (31b) and the second insertion portion 32a (32b) arranged in parallel inside the winding portion 2A (2B) is an insertion portion X, and the other is an insertion portion Y. Then, among the opposing surfaces that are one of the side surfaces of the insertion portion X and that face the insertion portion Y, the distal end side of the insertion portion X is separated such that a part of the distal end side of the insertion portion X A part is tapered. Specifically, the portions shown by dotted lines in FIGS.

  By cutting out a part of the distal end side of the insertion portion X, it is possible to form a gap in the parallel direction of the insertion portion X and the insertion portion Y on the distal end side of the insertion portion X. This gap contributes to the adjustment of the magnetic properties of the magnetic core. That is, the gap acts as an auxiliary gap. By forming such a gap, the distance between the separation parts 3AG and 3BG (the separation distance between the first divided core 31 and the second divided core 32 in the axial direction of the winding parts 2A and 2B) is not increased, and separation is performed. The adjustment effect of the magnetic property obtained by extending the distance can be obtained. If the separation distance is expanded, the leakage magnetic flux tends to increase at the positions of the separation parts 3AG and 3B. However, if the configuration is such that a gap is provided in the parallel direction of the insertion parts X and Y, the magnetic characteristics are suppressed The adjustment effect of can be obtained.

Seventh Embodiment
In the first to sixth embodiments, the reactor 1 including the coil 2 having the two winding parts 2A and 2B has been described. On the other hand, the reactor 10 provided with the coil 5 which has one winding part 5A, so-called pot-type reactor 10 will be described based on FIG.

  The coil 5 provided in the reactor 10 of the present example includes only one winding portion 5A, and the end portions 5a and 5b are drawn out from the one winding portion 5A.

  As shown in the upper drawing, the magnetic core 6 of the reactor 10 is divided into an inner core portion 6A, a first outer core portion 6C, a second outer core portion 6D, and a cylindrical outer core portion 6E for the sake of convenience. The division state of the magnetic core 6 is three, that is, the first divided core 61, the second divided core 62, and the third divided core 63, as shown in the lower diagram. The first split core 61 is configured by a first outer core portion 6C and a rod-like first insertion portion 61a integrally provided to the first outer core portion 6C. The second split core 62 is configured of a second outer core portion 6D and a cylindrical second insertion portion 62a integrally provided on the second outer core portion 6D. On the other hand, the third divided core 63 is constituted by a cylindrical outer core portion 6E. One end and the other end of the third divided core 63 are in contact with the first outer core portion 6C and the second outer core portion 6D, respectively. The cylindrical outer core portion 6E may be formed integrally with the first divided core 61 or the second divided core 62. In this case, the number of divisions of the magnetic core 6 is two.

  In this example, the length of the cylindrical second insertion portion 62a is shorter than that of the rod-like first insertion portion 61a. Therefore, the separation portion 6AG is formed on the upper side of the drawing of the inner core portion 6A. Of course, the length of the cylindrical second insertion portion 62a may be longer than that of the first insertion portion 61a, and the separation portion 6AG may be formed on the lower side of the inner core portion 6A in the drawing.

  Also in pot type reactor 10, the same effect as reactor 1 provided with a pair of winding parts 2A and 2B can be acquired.

Eighth Embodiment
The application of the reactor according to the first to seventh embodiments is, for example, an application in which the conduction condition is, for example, maximum current (direct current): about 100 A to about 1000 A, average voltage: about 100 V to about 1000 V, operating frequency: about 5 kHz to 100 kHz The present invention can be used as a component of a converter mounted on a vehicle such as an automobile or a hybrid vehicle, or a component of a power converter including the converter. In this application, it is expected that an inductance of 10 μH or more and 2 mH or less at a direct current conduction of 0 A and an inductance at a maximum current conduction of 10% or more of the inductance at 0 A can be suitably used.

  For example, a vehicle 1200 such as a hybrid car or an electric car is driven by power supplied from the main battery 1210, the power conversion device 1100 connected to the main battery 1210, and the main battery 1210 as shown in FIG. And a motor (load) 1220. The motor 1220 is typically a three-phase AC motor, which drives the wheels 1250 during 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. Although an inlet is shown as a charge part of vehicles 1200 in Drawing 8, it is good also as a form provided with a plug.

  Power converter 1100 has a converter 1110 connected to main battery 1210, and an inverter 1120 connected to converter 1110 to perform 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 approximately 200 V to 300 V to approximately 400 V to 700 V when vehicle 1200 is traveling, and feeds it to inverter 1120. At the time of regeneration, converter 1110 reduces the DC voltage (input voltage) output from motor 1220 via inverter 1120 to a DC voltage compatible with main battery 1210 to charge main battery 1210. Inverter 1120 converts the direct current boosted by converter 1110 into a predetermined alternating current and feeds it to motor 1220 while vehicle 1200 is traveling, converts the alternating current output from motor 1220 into direct current and outputs it to converter 1110 during regeneration. doing.

  Converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 for controlling the operation of switching elements 1111 and a reactor L as shown in FIG. 9, and conversion of input voltage by repetition of ON / OFF (switching operation) (In this case, boost and drop pressure). Power devices such as FETs and IGBTs are used as the switching elements 1111. The reactor L has the function of smoothing the change when the current is increased or decreased by switching operation, utilizing the property of the coil which tends to prevent the change of the current flowing into the circuit.

  Here, the vehicle 1200 is connected to the converter 1110 as well as the power supply device converter 1150 connected to the main battery 1210, and the sub battery 1230 and the main battery 1210 serving as the power source of the accessories 1240, and the main battery An accessory power supply converter 1160 is provided to convert the high voltage of 1210 to a low voltage. The converter 1110 typically performs DC-DC conversion, but the power supply device converter 1150 and the accessory power supply converter 1160 perform AC-DC conversion. Some of the power supply device converters 1150 perform DC-DC conversion. Reactors of the power supply device converter 1150 and the accessory power converter 1160 have the same configuration as that of the reactor of the above embodiment and the like, and reactors with appropriately changed sizes and shapes can be used. In addition, the reactor or the like of the above-described embodiment can be used as a converter that converts input power, and performs only boosting or reducing.

  The reactor of the present invention can be used as a reactor of a power conversion device such as a bidirectional DC-DC converter mounted on a vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle.

1, 10 reactor 2, 5 coil 2A, 2B, 5A winding part 2r connecting part 2a, 2b, 5a, 5b end part 3, 6 magnetic core 3A, 3B, 6A inner core part 3C, 6C first outer core part 3D , 6D second outer core portion 6E cylindrical outer core portion 31, 61 first split core 31a, 31b, 61a first insertion portion 32, 62 second split core 32a, 32b, 62a second insertion portion 63 third split core 3AG, 3BG, 6AG Separation part 4 Insulating member 1100 Power converter 1110 Converter 1111 Switching element 1112 Drive circuit L Reactor 1120 Inverter 1150 Converter for power supply 1160 Converter for accessory power supply 1200 Vehicle 1210 Main battery 1220 Main battery 1220 Sub battery 1240 Supplement Machinery 1250 wheels

Claims (7)

A reactor comprising: a coil having a winding portion; and a magnetic core having an inner core portion disposed inside the winding portion,
At least a part of the magnetic core is formed by combining a first divided core and a second divided core which are composed of a composite material in which a soft magnetic powder is contained in a resin,
The first divided core is integrally provided on a first outer core portion disposed on the outer side of the winding portion on one end side in the axial direction of the winding portion, and the first outer core portion, A first insertion portion inserted into the winding portion from one end face of the portion;
The second divided core is integrally provided on a second outer core portion disposed outside the winding portion on the other end side in the axial direction of the winding portion, and the second outer core portion, And a second insertion portion inserted into the winding portion from the other end face of the winding portion,
The inner core portion disposed inside the winding portion by arranging the first insertion portion and the second insertion portion inside the winding portion in a direction intersecting the axial direction of the winding portion. Is formed,
A separation part in which the first divided core and the second divided core are separated in the axial direction of the winding part is formed on any one end face side of the winding part ,
When one of the first insertion portion and the second insertion portion is the insertion portion X and the other is the insertion portion Y,
The insertion portion X is one of the side surfaces of the insertion portion X such that a part on the tip end side of the insertion portion X is separated from the insertion portion Y among the opposing surfaces facing the insertion portion Y A reactor in which a part on the tip side is tapered . A pair of the winding portions is provided, and the winding portions are arranged in parallel so that the axial direction of one winding portion and the axial direction of the other winding portion are parallel to each other,
The first divided core includes the first insertion portion inserted into each of the one winding portion and the other winding portion,
The second divided core includes the second insertion portion inserted into each of the one winding portion and the other winding portion.
The separation portion formed on the side of the one winding portion is disposed on one of the end surface side and the other surface side of the one winding portion,
The separation portion formed on the side of the other winding portion is disposed on the one end surface side and the other end surface side of the other winding portion on the opposite side to the separation portion in the one winding portion. The reactor according to claim 1.   The reactor according to claim 2, wherein the first insertion portion and the second insertion portion are arranged in parallel directions of both winding portions inside the one winding portion and the other winding portion. The reactor according to any one of claims 1 to 3 , wherein the first divided core and the second divided core have the same shape. The reactor according to any one of claims 1 to 4 , wherein both of the first insertion portion and the second insertion portion have a tapered shape in which the whole of the first insertion portion and the second insertion portion is tapered from the root side toward the tip side. A converter comprising the reactor according to any one of claims 1 to 5 . A power converter comprising the converter according to claim 6 .

Images