WO2015190215A1 - Reactor - Google Patents

Abstract

Provided is a reactor such that movements of a coil due to vibrations can be suppressed without a sealing material. The reactor is equipped with: a coil formed by spirally winding a winding wire; magnetic cores each having an inner core part disposed inside the coil; and coil fixation parts which comprise a foamed resin and restrict movement of the coil by means of volume expansion of the foamed resin. The coil fixation parts are equipped with inner interposition parts which are interposed between the inner circumferential surface of the coil and the outer circumferential surfaces of the inner core parts of the magnetic cores and turn interposition parts which are interposed between the turns of the coil.

Description

Reactor

The present invention relates to a reactor used for a vehicle-mounted DC-DC converter or a power converter component mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor that can suppress the movement of a coil due to vibration or the like even without a sealing material.

Reactor is one of the circuit components that perform voltage step-up and step-down operations. Patent Document 1 discloses a cylindrical coil formed by winding a winding spirally as a reactor used in a converter mounted on a vehicle such as a hybrid vehicle, and an annular magnetic core on which the coil is disposed. A case is disclosed that includes a case that accommodates a combination of a coil and a magnetic core, and a sealing material that is filled in the case and seals the combination. The entire assembly is fixed to the case by the sealing material.

JP 2006-351719 A

There is a demand for a reactor that can suppress the movement of the coil due to vibrations or the like even if it does not include a sealing material.

In the case where a sealing material is provided as in the reactor described in Patent Document 1, a case in which the sealing material is filled is indispensable, so that the reactor including the case tends to be large. Since it is desired that the installation space is small for in-vehicle applications, it is desirable to omit the sealing material and the case filled with the sealing material in consideration of further miniaturization of the reactor. Further, during operation of the reactor, the coil generates heat and the temperature rises, so it is desirable to cool it. For example, although heat dissipation can be enhanced by performing forced cooling with a liquid refrigerant, the coil cannot directly contact the liquid refrigerant when the coil is covered with a sealing material. It is conceivable to omit the sealing material from the viewpoint of improving the heat dissipation. However, if the sealing material is omitted, the coil cannot be fixed by the sealing material, and the coil expands and contracts in the axial direction due to vibration during operation, or the coil is deformed in the radial direction and the turn is shifted. Can move. As a result of the movement of the coil, the position of the coil with respect to the magnetic core may be shifted.

Here, in a reactor for in-vehicle use, vibration can be applied to the coil during its operation. This vibration is, for example, vibration generated from the traveling vehicle itself, vibration due to magnetostriction of the magnetic core, or the like. If the above-mentioned sealing material is omitted, the vibration may cause the coil to move, the coil and the magnetic core may be damaged by rubbing or colliding, or the turns may be rubbing or colliding. There is a risk of damaging the insulation coating of the windings constituting the coil or causing the above-mentioned displacement. In addition, noise or the like due to the above-described collision may occur.

Therefore, one of the objects of the present invention is to provide a reactor that can regulate the movement of a coil caused by vibrations or the like without having a sealing material.

The reactor which concerns on 1 aspect of this invention has a coil formed by winding a coil | winding helically, a magnetic core which has an inner core part arrange | positioned in the said coil, and foaming resin, The volume of the said foaming resin A coil fixing portion that restricts the movement of the coil by expansion. The coil fixing portion includes an inner interposed portion interposed between an inner peripheral surface of the coil and an outer peripheral surface of the inner core portion, and a turn interposed portion interposed between the turns of the coil.

Even if the above reactor does not have a sealing material, it can regulate the movement of the coil due to vibration or the like.

It is the schematic perspective view which shows the reactor of Embodiment 1, and the fragmentary sectional view explaining the state between the turns of a coil. FIG. 2 is a cross-sectional view of the reactor according to the first embodiment, taken along the line (II)-(II) shown in FIG. FIG. 3 is an exploded perspective view illustrating a manufacturing process of the reactor according to the first embodiment. It is a schematic perspective view which shows the reactor of Embodiment 2-1. FIG. 10 is an exploded perspective view illustrating a manufacturing process of the reactor according to the embodiment 2-1. FIG. 5 is a longitudinal sectional view of the reactor of Embodiment 2-2, cut along a plane parallel to the axial direction of the coil. It is a schematic perspective view which shows the reactor of Embodiment 3. FIG. 8 is a cross-sectional view of the reactor of the third embodiment, taken along the (VIII)-(VIII) section line shown in FIG. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 3. FIG. It is a schematic perspective view which shows the reactor of Embodiment 4. FIG. 11 is a cross-sectional view of the reactor according to the fourth embodiment, which is cut along a (XI)-(XI) cutting line shown in FIG. 10. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 4. It is a schematic perspective view which shows the reactor of Embodiment 5. FIG. 14 is a cross-sectional view of the reactor of the fifth embodiment, taken along the (XIV)-(XIV) section line shown in FIG. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 5. It is a schematic perspective view which shows the reactor of Embodiment 6. FIG. FIG. 17 is a cross-sectional view of the reactor according to the sixth embodiment, which is cut along a (XVII)-(XVII) cutting line shown in FIG. 16. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 6. FIG. It is a schematic perspective view which shows the reactor of Embodiment 7. FIG. FIG. 20 is a cross-sectional view of the reactor according to the seventh embodiment, which is cut along a (XX)-(XX) cutting line shown in FIG. 19. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 7. FIG. It is a schematic perspective view which shows the reactor of Embodiment 8. FIG. 23 is a transverse cross-sectional view of the reactor according to the eighth embodiment, taken along the line (XXIII)-(XXIII) shown in FIG. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 8. It is the reactor of Embodiment 9, Comprising: It is the cross-sectional view cut | disconnected by the plane orthogonal to the axial direction of a coil. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 9. It is the reactor of Embodiment 10, Comprising: It is the cross-sectional view cut | disconnected by the plane orthogonal to the axial direction of a coil. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 10. FIG. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 11. FIG. It is the reactor of Embodiment 12, Comprising: It is the cross-sectional view cut | disconnected by the plane orthogonal to the axial direction of a coil. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 12. FIG. It is a disassembled perspective view explaining the manufacturing process of the reactor of Embodiment 13. FIG. 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit diagram which shows an example of a power converter device provided with a converter.

[Description of Embodiment of the Present Invention]
First, embodiments of the present invention will be listed and described.

(1) A reactor according to an aspect of the present invention includes a coil formed by winding a winding in a spiral shape, a magnetic core having an inner core portion disposed in the coil, and a foamed resin. A coil fixing portion that restricts the movement of the coil by the volume expansion of the resin. The coil fixing portion includes an inner interposed portion interposed between the inner peripheral surface of the coil and the outer peripheral surface of the inner core portion, and a turn interposed portion interposed between the turns of the coil.

The above reactor is interposed in a state where the resin is foamed at least partially between the coil and the inner core portion, that is, in a state where the volume is expanded including bubbles. This foamed resin fills the gap between the coil and the inner core portion. Therefore, the movement of the coil that deforms in the radial direction or expands and contracts in the axial direction is suppressed and is fixed to the inner core portion. In addition, expansion and contraction of the coil is easily suppressed from the point that a part of the foamed resin is interposed between the turns of the coil and the interval between the turns is regulated by the foamed resin. As described above, the reactor in which the foamed resin is present on the inner peripheral surface of the coil and in the vicinity thereof does not include a sealing material that covers the outer peripheral surface of the coil. Can suppress movement. When the foamed resin has adhesive force, the coil fixing part can be firmly attached to both the coil and the inner core part by the adhesive force of the resin itself, or can be closely attached to each turn, thereby firmly fixing the coil. it can. For example, the above reactor can have both the effects of both the volume expansion of the foamed resin and the adhesive strength of the resin itself when fixing the coil. The above reactor is provided with a foamed resin at a specific location to improve the stability of the position of the coil relative to the magnetic core, to reduce the friction / collision between the coil and the magnetic core, and to prevent the friction / collision between turns. In addition, it is possible to prevent the coil insulation coating from being damaged, the magnetic core from being damaged, and noise from being prevented.

In addition, the reactor described above is excellent in heat dissipation because the coil can be directly brought into contact with the liquid refrigerant when it is cooled by the liquid refrigerant by omitting the sealing material.

The above reactor can be easily manufactured by, for example, disposing an unfoamed resin between the coil and the inner core portion and then performing a heat treatment necessary for foaming. The thickness of the unfoamed resin is much thinner than the thickness of the resin after foaming, and even if the gap between the coil and the inner core portion is narrow (for example, 2 mm or less), it can be easily arranged. At the time of foaming, a part of the resin enters between turns to form a turn interposition part, and the remaining part forms an inner interposition part. The turn interposition part also functions as an insulating material between turns.

(2) As an example of the reactor, a form in which the inner core portion includes a concave portion in which the foamed resin is disposed can be cited.

The recess can be used for positioning and holding unfoamed resin in the manufacturing process of the reactor. In particular, when the depth of the recess is made deeper than the thickness of the unfoamed resin, the coil and the unfoamed resin are unlikely to rub against each other when the coil and the inner core portion on which the unfoamed resin is placed are assembled. When the unfoamed resin is a solid such as a sheet, it is possible to prevent misalignment and dropping due to rubbing, and when the unfoamed resin is sticky, it can be prevented from peeling and easy to assemble. When the unfoamed resin is in a liquid state, it can be prevented from adhering to or leaking from an inappropriate location, and can be easily assembled. And the coil fixing part after foaming is also difficult to shift. From these points, the above-mentioned form is excellent in assembling workability, and it is easy to maintain the fixed state of the coil for a long time. Furthermore, since a part of the foamed resin is disposed in the concave portion, the amount of resin protruding from the concave portion can be reduced. As a result, the interval between the coil and the inner core portion can be narrowed. From this point, the above-mentioned form can be made small.

(3) As an example of a reactor including the concave portion of (2) above, the inner core portion includes a middle main body portion serving as a magnetic path, and a middle resin mold portion covering at least a part of the outer peripheral surface of the middle main body portion. It is provided that the concave portion is provided in the middle resin mold portion.

The above form is further excellent in assembling workability in addition to being easy to maintain the fixed state of the coil as in the above form (2). Even if the gap between the two is small due to the dimensional tolerance of the coil or middle resin mold part, it is possible to prevent rubbing and adhesion between the coil and the unfoamed resin by arranging the unfoamed resin in the recess. It is. Moreover, since the said form equips a middle resin mold part with a recessed part, there is substantially no reduction | decrease in the magnetic path resulting from presence of a recessed part, and it is excellent in a magnetic characteristic. In addition, in this embodiment, by providing the middle resin mold portion, in addition to ensuring insulation between the coil and the middle body portion, it is possible to achieve mechanical protection of the middle body portion and protection from the external environment.

(4) As an example of a reactor including the concave portion of (2) above, the inner core portion includes a middle main body portion serving as a magnetic path, and a middle resin mold portion covering a part of the outer peripheral surface of the middle main body portion. In addition, a bottomed hole including an inner wall portion made of a constituent resin of the middle resin mold portion surrounding the exposed portion is formed with the exposed portion not covered by the middle resin mold portion in the middle main body portion as a bottom portion, The form in which the said recessed part contains the said bottomed hole is mentioned.

This form has the same effect as the above-mentioned (3), that is, maintaining the fixed state of the coil by the foamed resin, good assembling workability by disposing the unfoamed resin in the recess, and reducing the magnetic path due to the recess. There are effects such as prevention and protection of the middle main body by providing the middle resin mold. In particular, in the above-described embodiment, the foamed resin is in contact with the exposed portion of the middle main body, and the exposed portion can be mechanically protected and protected from the external environment by the foamed resin instead of the middle resin mold portion. For this reason, it is possible to suppress the local deterioration of the magnetic characteristics due to local damage or corrosion of the exposed portion. If the bottomed hole is relatively small, such as formed by a jig that supports the middle body in a predetermined position in the mold when molding the middle resin mold, When a liquid resin is used as the foamed resin, the recess including the bottomed hole can be easily filled with the unfoamed resin, and the workability is excellent.

(5) As an example of the reactor of the above (4) provided with the concave portion of the bottomed hole, a groove portion having a groove bottom portion where the middle resin mold portion is continuous with the opening edge of the bottomed hole is provided, and the concave portion May include the bottomed hole and the groove.

This form has the same effect as the above-mentioned form (4). Furthermore, since this form is provided with a bottomed hole and a groove part, an unfoamed resin can be arranged in the groove part in addition to the bottomed hole.For example, the exposed part of the middle main body part can be reduced by reducing the bottomed hole. Can be reduced. Even in this case, if the opening of the groove and the bottom of the groove are sufficiently larger than the opening of the bottomed hole, and an unfoamed resin is disposed in the groove, a sufficient amount of unfoamed resin can be disposed in the recess. In this way, it is possible to satisfactorily maintain the fixed state of the coil by the foamed resin. The above-described coil and unfoamed resin can be prevented from rubbing and adhering, and the assembly workability is excellent.

(6) As an example of a reactor including the recess of (2) above, a form in which the inner core portion includes a middle main body portion serving as a magnetic path, and the recess portion is provided in the middle main body portion.

In the above embodiment, it can be said that at least a part of the foamed resin is disposed in direct contact with the middle main body, and that there is a portion where only the foamed resin exists between the coil and the middle main body. This portion has a small distance between the inner peripheral surface of the coil and the outer peripheral surface of the inner core portion (hereinafter referred to as a coil-core distance). Since the amount of resin protruding from the recess can be reduced as described above, the distance between the coil and the core can be further reduced. From these points, the above-mentioned form is small. In addition to the fact that the coil is easily maintained in the fixed state as in the above-described form (2), the above-described form is provided with a recess even when the distance between the coil and the core is small. Excellent workability.

(7) As an example of the reactor, a form in which the inner intervening portion is provided over the entire length of the inner core portion can be given.

In the above embodiment, it can be said that the inner intervening portion exists over the entire axial length of the coil. Therefore, the said form can suppress more the movement of a coil, especially the expansion-contraction of the axial direction of a coil.

(8) As an example of the reactor, a form in which the turn interposition part is interposed in a region between the turns of the coil and does not reach the outer peripheral surface of the coil.

In the above embodiment, when the sealing material for covering the coil is not provided, the outer peripheral surface of the coil is exposed, and a slight gap is provided between the turns by the turn interposition part. Therefore, for example, when cooling the reactor of the said form with a liquid refrigerant, the outer peripheral surface of a coil can contact a liquid refrigerant directly, or the liquid refrigerant can be filled into the clearance gap between turns, and a coil can be cooled effectively. . Therefore, the said form can improve the heat dissipation of a coil, and is excellent in heat dissipation. Moreover, the amount of unfoamed resin used at the time of manufacture may be comparatively small, and the said form can reduce the said resin amount. This is because the resin amount may be such that the turn interposition part does not reach the outer peripheral surface of the coil.

(9) As an example of the reactor, the inner core portion includes a middle main body portion serving as a magnetic path, and a middle resin mold portion covering at least a part of the outer peripheral surface of the middle main body portion, and the coil fixing portion The form with which at least one part is provided in contact with the said middle resin mold part is mentioned.

In the above embodiment, it can be said that the coil fixing portion has a portion provided in contact with both the coil and a region where the middle resin mold portion in the inner core portion is present (for example, the entire inner core portion). This portion is small because only the foamed resin and the middle resin mold portion exist between the coil and the middle main body portion, and the distance between the coil and the core is relatively small. In addition, in the same manner as the above (3) to (5) including the middle resin mold portion, the middle resin mold portion prevents insulation between the coil and the middle main body portion, mechanical protection of the middle main body portion, and external environment. There are effects such as protection.

(10) As an example of the reactor, a form in which the inner core portion includes a composite material including a soft magnetic powder and a resin can be given.

The above-described configuration including the coil fixing portion and including the composite material in the inner core portion, preferably the configuration in which the entire inner core portion is substantially composed of the composite material is provided between the coil and the core for the following two reasons. The distance can be made smaller and smaller. The above configuration is smaller when the insulating material called the above-mentioned resin mold part or bobbin is not interposed between the coil and the inner core part, and substantially only the foamed resin exists.
(I) Since the composite material includes a resin component, it is easy to lower the relative permeability and shorten the gap (thinner) compared to a compacted body or a laminated body of magnetic steel sheets that are widely used for magnetic path members. Or the gap can be omitted. As a result, the leakage magnetic flux from the gap portion can be reduced and the loss (copper loss) resulting from this leakage magnetic flux can be reduced, so that the coil and the inner core portion can be arranged close to each other. As a result, the distance between the coil and the core can be reduced (for example, 2 mm or less).
(II) Since the composite material includes a resin component, it is easy to improve the insulation as compared with the above compacted body and the like, and the electrical insulation distance between the coil and the inner core portion can be reduced. As a result, the distance between the coil and the core can be reduced (for example, 2 mm or less). When the above-described insulating material is not interposed, the foamed resin also functions as an insulating material and contributes to the insulation between the coil and the inner core portion.

(11) As an example of the reactor of the above (10), there is a form in which the coil fixing portion is provided in contact with the composite material.

In the above embodiment, it can be said that the coil fixing portion has a portion provided in contact with both the coil and the region made of the composite material in the inner core portion (preferably the entire inner core portion). In this part, only the foamed resin exists between the coil and the inner core part, and the distance between the coil and the core is substantially equal to the thickness of the foamed resin (the average thickness of the inner interposition part), and is small. is there. In this embodiment, the coil fixing portion functions as an insulating material between the coil and the composite material of the inner core portion in addition to the insulation between the turns. Therefore, the said form can abbreviate | omit insulating materials, such as the above-mentioned resin mold part and a bobbin.

(12) As an example of the reactor described above, a form in which the inner intervening portion is provided in a part of the circumferential direction in the cylindrical inner circumferential space between the coil and the inner core portion can be cited.

In the above form, it can be said that there is a portion where the foamed resin does not exist in a part of the inner circumferential space. Even if the foamed resin is not present over the entire circumference or the entire length of the inner circumferential space, the gap between the coil and the inner core portion is filled by the volume expansion of the foamed resin as described above, Sufficient strength for fixing can be obtained. When the foamed resin has an adhesive force, the coil fixing strength is further improved. Therefore, the above-described form can suppress the movement of the coil, and can be expected to reduce the amount of unfoamed resin used at the time of manufacture, and to improve the heat dissipation by being able to fill the gap in the inner peripheral space with the above-described liquid refrigerant. . Moreover, since the said form should just arrange | position unfoamed resin only to a part of circumferential direction of inner peripheral space, it is excellent also in productivity from the point which can arrange | position unfoamed resin easily.

(13) As an example of the reactor, a form in which the distance between the inner peripheral surface of the coil and the outer peripheral surface of the inner core portion is 2 mm or less can be given.

The above configuration is small with a sufficiently small distance between the coil and the core.

(14) As an example of the reactor, a form in which the inner core portion includes a green compact is cited.

Since the compacted compact has a relatively high saturation magnetic flux density, the inner core portion includes the compacted compact, and preferably the entire magnetic component of the inner core section is the compacted compact. The cross-sectional area can be reduced. Therefore, the said form can make an inner core part small, and can aim at size reduction of a reactor by extension. Moreover, when the said form is provided with the above-mentioned middle resin mold part, the insulation between a coil and a compacting body can be improved.

The magnetic core provided in the above reactor typically includes a core piece made of a compacted body or a core piece made of a composite material. Table 1 shows typical forms of the inner core portion of the magnetic core provided in the reactor. The form which combined the structure shown in Table 1 can also be taken. The combined form is, for example, a form in which the magnetic component of the middle main body part is only a powder molded body and includes a part having no resin mold part and a part having the resin mold part, and the middle main body part includes both the powder molded body and the composite material. The form provided is mentioned. Furthermore, a combination form such as a form in which the inner core part includes a core piece including a resin mold part and a bare core piece not including the resin mold part is included.

[Details of the embodiment of the present invention]
Hereinafter, a reactor according to an embodiment of the present invention will be specifically described with reference to the drawings. The same code | symbol in a figure shows the same name thing.

[Embodiment 1]
The reactor 1A according to the first embodiment will be described with reference to FIGS. In the following embodiment, the state shown in FIG. 1, FIG. 4, FIG. 7, FIG. 10, FIG. 13, FIG. 16, FIG. This will be described as a state. This installation state is an exemplification, and can be set to an installation state in which the side surface and the upper surface are the installation surface.

(Reactor)
-Overall configuration Reactor 1A has a coil 2 formed by spirally winding wire 2w, and an inner core portion disposed in coil 2, and is disposed inside and outside coil 2 to form a closed magnetic circuit. A core 3A. Typically, the reactor 1A is attached to an installation target (not shown) such as a converter case in such a state that the outer periphery of the combined body 10 including the coil 2 and the magnetic core 3A is not covered with the sealing material. Used. The reactor 1A includes a coil fixing portion 4 that is mainly interposed between the coil 2 and the inner core portion (here, the inner core component 310A) and restricts the movement of the coil 2, and the coil fixing portion 4 is made of foam resin. One of the features is that it has. Hereinafter, the outline of the coil 2 and the magnetic core 3A that are the main constituent members of the reactor 1A, the coil fixing portion 4 that is the characteristic point, the related configuration, and the main effects based on the characteristic point will be described in order. explain in detail.

Coil outline The coil 2 shown in this example has a pair of cylindrical winding portions 2a and 2b formed by spirally winding one continuous winding 2w as shown in FIGS. And a connecting portion 2r that is formed from a part of the winding 2w and connects the winding portions 2a and 2b. Each winding part 2a, 2b is arranged in parallel (side by side) so that each axial direction is parallel. The winding 2w shown in this example is a covered flat wire including a flat wire conductor and an insulating coating covering the outer periphery of the conductor, and the winding portions 2a and 2b are edgewise coils. In this example, each winding part 2a, 2b is the shape which rounded the corner part inside and outside of a square cylinder. Since the inner peripheral surface of each winding part 2a, 2b is an edgewise coil, it has a uniform surface shape, and four curved surfaces (surfaces forming corners) connecting four adjacent planes. ) (See FIGS. 2 and 3).

Both ends 2e and 2e of the winding 2w are drawn out in appropriate directions from the turn portions of the winding portions 2a and 2b. In each of the end portions 2e and 2e, the insulating coating is peeled off to expose the conductor (in this case, a flat wire), and a terminal fitting (not shown) is connected to the exposed portion by welding or the like. The coil 2 is electrically connected to an external device (not shown) such as a power source via a terminal fitting.

Outline of magnetic core The magnetic core 3A includes an inner core portion disposed in the coil 2 (winding portions 2a and 2b) and an outer core portion that is not substantially disposed and protrudes from the coil 2. Prepare. The magnetic core 3A shown in this example includes a core component in which a part for constructing a magnetic path is covered with a resin.

As shown in FIG. 3, the part for constructing the magnetic path includes a pair of columnar (here, rounded corners of a rectangular parallelepiped) middle main bodies 31 and 31, a pair of columnar side main bodies 32 and 32, and Mainly. These main body portions 31 to 32 are mainly composed of a soft magnetic material. The magnetic core 3A includes inner core parts 310A and 310A in which the middle main body portions 31 and 31 are covered with middle resin mold portions 310m and 310m, respectively, and the side main body portions 32 and 32 are covered with the side resin mold portions 320m and 320m, respectively. A total of four core parts including the outer core parts 320 and 320 are provided.

Each inner core part 310A, 310A constitutes an inner core part, and each outer core part 320, 320 constitutes an outer core part. By assembling the outer core parts 320 and 320 so as to connect both the inner core parts 310A and 310A arranged side by side, the middle main body parts 31 and 31 and the side main body parts 32 and 32 are arranged in an annular shape, and the coil 2 is excited. Sometimes forms a closed magnetic circuit. In this example, both the main body portions 31 and 32 are each provided with a green compact, and the middle resin mold portion 310m and the side resin mold portion 320m are made of polyphenylene sulfide (PPS) resin. The middle main body 31 includes a core piece 31m made of a compacted body and a gap member 31g made of a material having a relative permeability smaller than that of the core piece 31m (see the broken line circle in FIG. 3).

When the magnetic core 3A is annularly assembled, the upper surface of the middle main body 31 and the upper surface of the side main body 32 are substantially flush with each other, and the lower surface of the side main body 32 is the lower surface of the middle main body 31. Than protruding. The inner core component 310 </ b> A and the outer core component 320 have substantially similar shapes along the outer shape of the middle main body 31 and the outer shape of the side main body 32. Moreover, the lower surface of the outer core part 320 in the assembly 10 and the lower surface of the coil 2 (winding portions 2a, 2b) are substantially flush. Therefore, the installation surface of the reactor 1A (combination body 10) shown in this example is mainly composed of the lower surface (installation surface) of the two outer core components 320 and 320 and the lower surface of the coil 2 (installation surface of the winding portions 2a and 2b). ).

The inner end surface 320e of the outer core component 320 is a surface including a core connection region to which the end surface 310e of the inner core component 310A is connected and a coil facing region facing the end surface of the coil 2 (winding portions 2a and 2b). . Here, the core connection region is a region where the inner end face 32e of the side main body portion 32 is exposed, and the coil facing region is a region covered with the side resin mold portion 320m, both of which are configured as a plane. . In addition, the coil facing region is configured by the adjacent sides of the winding parts 2a and 2b, the lower side, and the corners connecting the two sides of the end faces of the winding parts 2a and 2b. These are two L-shaped regions facing the L-shaped portion to be formed.

-Coil fixing part The coil fixing part 4 is comprised with the foaming resin, and exists in the state which carried out the volume expansion including the bubble by foaming. The coil fixing portion 4 shown in this example is in close contact with the coil 2 and the inner core portion by the adhesive force of the resin itself. The coil fixing portion 4 includes an inner interposition portion 40 and a turn interposition portion 42 as shown in an enlarged manner in the broken-line circle in FIG. Furthermore, the coil fixing part 4 of this example also includes an end fixing part 44. 1 is a partially enlarged cross-sectional view taken along a cutting line (A)-(A) shown in FIG. 1, that is, a cross-sectional view taken along a plane parallel to the axial direction of the coil 2.

.. Inner interposition part The inner interposition part 40 is a cylindrical shape formed between the inner peripheral surface of the coil 2 (winding parts 2a, 2b) and the outer peripheral surface of the inner core part (inner core parts 310A, 310A). In the inner peripheral space, the intermediate space is interposed in at least a part of the circumferential direction. In this example, as shown in FIG. 2, a plurality of inner interposition portions 40, 40 exist at opposing positions in the cylindrical inner circumferential space. By performing the volume expansion described above in the inner space substantially in the inner space in the manufacturing process described later, the inner interposition part 40 contacts the coil 2 and the inner core part in the inner space, By inhibiting the contact between the two, the movement of the coil 2 is regulated. The coil fixing part 4 in this example regulates the movement of the coil 2 because it is in close contact with both the coil 2 and the inner core part by the adhesive force of the resin itself. 2, FIG. 11, FIG. 14, FIG. 17, FIG. 20, FIG. 20, FIG. 23, FIG. 25, FIG. 27, and FIG. 30 are all cross-sectional views cut along a plane orthogonal to the axial direction of the coil. It is.

In this example, as shown in FIG. 2, the inner interposition portions 40 and 40 are respectively provided with upper and lower planes of the inner peripheral surfaces of the winding portions 2a and 2b, and the inner core components 310A, It is arranged between the upper and lower planes of the outer peripheral surface of 310A. In other words, the inner interposition portions 40 and 40 in one winding portion are respectively disposed at upper and lower opposing positions in the inner circumferential space, and are provided only in a part of the inner circumferential space in the circumferential direction. There is no foamed resin in the other circumferential direction of the inner circumferential space, and there is a gap. Further, in this example, the inner interposition portions 40, 40 are provided in direct contact with the middle resin mold portion 310m over the entire length of the inner core components 310A, 310A (see the broken line in FIG. 1).

... Existence state in the circumferential direction A form having one inner interposition part 40 continuous in the circumferential direction of the inner circumferential space (see Embodiments 9 to 12 described later), as shown in this example, Any of the embodiments (in addition to this example, Embodiments 2-1, 2-2, 3 to 8, 13 to be described later) provided with a plurality of independent inner interposed portions 40 that are not continuous in the direction may be employed. The former form is excellent in manufacturability because there are few arrangement steps of unfoamed resin in the production process. In the latter form, since there are a plurality of fixing portions for each of the winding portions 2a and 2b of the coil 2, the fixing strength of the coil 2 can be increased and a plurality of gaps provided between the adjacent inner interposition portions 40 and 40 can be provided. It exists and can utilize these some clearance gaps for the filling location of the above-mentioned liquid refrigerant.

Further, as shown in this example, a mode in which inner interposition portions 40 are provided at opposing positions in the inner circumferential space (in addition to this example, Embodiments 2-1, 2-2, to 9, 11 to 13 described later), Any of the forms (refer to Embodiment 10 described later) including the inner interposition part 40 arranged so as not to include the facing position may be used. In the former form, the coil 2 can be fixed uniformly by the inner interposition part 40 along the circumferential direction of the winding parts 2a and 2b. The latter form can easily arrange the unfoamed resin in the manufacturing process, and is excellent in manufacturability.

When the inner intervening portion 40 is a continuous one, for example, (α) a form that exists in the entire length in the circumferential direction of the inner circumferential space, (β) it exists only in a part in the circumferential direction of the inner circumferential space. It can be in the form. For example, the form (β) can include a facing position of the inner peripheral space by being present in a C shape along the inner peripheral space. When the inner circumferential space is a rectangular frame shape having a flat portion and a curved portion (corner portion) as in this example, out of the four corner portions of the rectangular frame, two corner portions and a flat portion in the vicinity thereof, Alternatively, it is possible to include a C-shaped inner interposition part 40 disposed in three corners and a flat part in the vicinity thereof (see Embodiments 9, 11, and 12 described later). In addition, a form including an L-shaped inner interposition part 40 disposed including one corner part and a flat part sandwiching the corner part among the four corner parts (see Embodiment 10 described later), The form etc. which are provided with the inner side interposition part 40 arrange | positioned along a flat part without including the said corner | angular part are mentioned.

In the case where there are a plurality of inner intervening portions 40 in the circumferential direction of the inner circumferential space, for example, (γ) a form that exists at the left and right opposing positions of the inner circumferential space or an upper and lower opposing position of the inner circumferential space. Forms (see Embodiments 2-2 and 13 described later in addition to this example), (δ) Forms present in the upper and lower facing positions and the left and right facing positions of the inner space (described later Embodiments 2-1 and 3) , 4, 6 and 7), (ε) a form existing at two diagonal positions in the inner space, and (ζ) a form present at four diagonal positions in the inner space (described later). For example). When the inner circumferential space has a rectangular frame shape including a flat portion and a curved portion (corner portion) as in this example, in the form (γ), one inner interposition portion 40 is formed in the flat portion of the inner circumferential space. (Fig. 2). In the forms (ε) and (ζ), for example, one inner interposition part 40 is formed into an L shape including one corner of the inner space and a flat part sandwiching the corner, For example, a J-shape including a corner portion and a flat portion connected to the corner portion or a shape (curved shape) along a rounded corner portion as shown in the fifth and eighth embodiments can be given. . FIG. 2 shows a form (γ) in which a plurality of inner intervening portions 40 exist at upper and lower opposing positions in the inner circumferential space.

... Existence state in the axial direction Form including one inner interposition part 40 continuous in the axial direction of the inner peripheral space, not including the inner intervening parts 40 independent of the axial direction of the inner peripheral space Any of the forms (see Embodiments 3 to 8 and 10 to 13 described later) may be used. In the case of including the former one continuous inner interposition part 40, for example, (i) a form existing in the entire axial length of the inner circumferential space, (ii) present only in a part of the inner circumferential space in the axial direction. It can be in the form (Embodiments 2-1, 2-2, 9 described later). FIG. 1 shows the form (Α). When the latter plurality of inner intervening portions 40 are present, the number thereof can be selected as appropriate. When the inner intervening portion 40 exists only in a part of the inner circumferential space in the axial direction, it is preferable to further include an end fixing portion 44 described later because the coil 2 can be more firmly fixed.

... Size of the inner interposition part 40 along the circumferential direction of the inner circumferential space (total length in the case of multiple pieces), length along the axial direction (total length in the case of multiple pieces) Can be selected as appropriate. The longer the length, the larger the contact area of the inner interposition part 40 with the coil 2, the easier it is to regulate the movement of the coil 2, and the better fixing strength of the coil 2. Therefore, in consideration of fixing of the coil 2, the length along the circumferential direction of the inner interposition part 40 is preferably 15% or more, more preferably 20% or more, 25% or more of the circumferential length of the inner circumferential space. 30% or more, 50% or more, further 75% or more, and the length along the axial direction is preferably 25% or more of the axial length of the inner circumferential space, and more preferably 50%. As mentioned above, it can be 75% or more, and also 90% or more.

On the other hand, if the existence area of the inner interposition part 40 is small, a gap is provided in the above-described inner circumferential space, and this gap can be used as a contact area between the coil 2 and the liquid refrigerant described in a later-described use example. Moreover, the material used for the inner interposition part 40 can be reduced. For example, in the above-described inner circumferential space, if the gap is provided in the region close to the liquid refrigerant supply unit without the inner interposition part 40, the contact region with the liquid refrigerant can be secured at a suitable position, and the heat dissipation can be improved. Enhanced. In the case where the reactor 1A is attached to an installation target provided with a cooling mechanism instead of a cooling structure by direct contact with a liquid refrigerant, for example, the inner interposition part 40 is provided in a region close to the installation target in the inner peripheral space described above. If the heat dissipation sheet is not present, and a heat dissipation sheet having high heat conductivity and excellent heat dissipation is interposed, the heat dissipation can be improved. Considering these points (improvement of heat dissipation, reduction of material), the length along the circumferential direction is 95% or less, further 90% or less, and further 80% or less of the circumferential length of the coil 2. Is preferred. In the first embodiment, the length along the axial direction is about 100%, and the length along the circumferential direction is about 40% of the circumferential length of the inner circumferential space.

The average thickness 4t of the inner interposed portion 40 is the distance between the inner peripheral surface of the coil 2 (winding portions 2a, 2b) and the outer peripheral surface of the inner core portion (inner core components 310A, 310A) (coil-core). Typically) and is substantially equal to this distance. Therefore, it can be said that the shorter the distance, the thinner the average thickness 4t. Here, the shorter the distance between the inner peripheral surface of the winding portions 2a and 2b and the outer peripheral surface of the middle main body portions 31 and 31 (hereinafter referred to as the distance between the coil and core main body), the shorter the coil 2 and the inner core. And the reactor 1A become small. Therefore, considering the miniaturization, the distance between the coil and the core body is preferably 3 mm or less, more preferably 2.5 mm or less, particularly 2 mm or less, 1.8 mm or less, and further preferably 1.5 mm or less. In this example, the average thickness 4t is thinner than the distance between the coil and the core body by the thickness of the middle resin mold portion 310m, so it is 2 mm or less, 1.8 mm or less, 1.5 mm or less, and further 1 mm or less. It can be. In this example, the distance between the coil and the core body is 2.5 mm or less, the average thickness 4 t is 1 mm or less, and the thickness of the mold part 310 m is 2 mm or less.

..Turn interposition part The turn interposition part 42 is interposed between at least one pair of adjacent turns 2t and 2t among adjacent turns 2t and 2t of the coil 2 as shown in a broken-line circle in FIG. . In this example, the turn interposition part 42 exists only in the middle of the turn 2t from the inner peripheral surface of the winding parts 2a and 2b outward. That is, the turn interposition part 42 exists only in the vicinity of the inner peripheral surface of the winding parts 2a and 2b, and exists in a region that does not reach the outer peripheral surface of the coil 2 (this is the same in the embodiments described later). is there). This turn interposition part 42 is continuous with the above-mentioned inner interposition part 40, and a part of the foamed resin constituting the inner interposition part 40 enters the vicinity of the above-mentioned inner peripheral surface between the adjacent turns 2t and 2t. It is a part that exists. In the example shown in FIG. 1, a case where the turn interposition part 42 exists between all adjacent turns 2 t and 2 t is shown, but it is allowed that there exists a turn 2 t and 2 t where no turn interposition part 42 exists. .

Here, the turn portion of the coil 2 (winding portions 2a, 2b) is sandwiched between the two outer core parts 320, 320, and the length in the axial direction thereof is regulated. In the manufacturing process to be described later, volume expansion of the above-described foamed resin is performed in such a regulation section, so that the turn interposition portion 42 is interposed between adjacent turns 2t and 2t by this volume expansion, and turns 2t, The contact between 2t is inhibited and the movement of the coil 2 (especially the movement in the axial direction) is restricted.

Since the movement of the coil 2 can be sufficiently restricted by the presence of the inner interposition part 40, the number of the turn interposition parts 42, the height 4H (the outer periphery from the inner peripheral surface of the coil 2 (winding part 2a, 2b) in the turn 2t) The distance in the direction toward the surface) and the thickness (substantially equal to the distance between adjacent turns 2t, 2t) are not particularly limited. As will be described later, when the turn interposition part 42 is formed by the resin automatically entering between the adjacent turns 2t and 2t when the resin is foamed, the number of the turn interposition parts 42, the height 4H, the thickness This is because it is substantially difficult to control as designed. The greater the number of turn interposition parts 42, the higher the height 4H, or the thicker the thickness, the easier it is to spread between the turns 2t and 2t by the turn interposition part 42, and the movement of the coil 2 is easier to regulate. The height 4H is 50% or less, 25% or less, 20% or less, or even 10% or less of the height of the turn 2t (here, equal to the width w of the covered rectangular wire that is the winding 2w). Contribute to the regulation of

.. End fixing portion The end fixing portion 44 includes an end surface of the coil 2 (winding portions 2a and 2b) and an inner end surface of the outer core portion facing the end surface of the coil 2 (inner end surfaces of the outer core components 320 and 320). 320e, 320e). In this example, the end fixing portions 44 and 44 are L-shaped between the end surfaces of the respective winding portions and the above-described L-shaped coil facing region of the inner end surface 320e of the outer core component 320. Intervene. In the reactor 1A, a total of four L-shaped end fixing portions 44 are provided. The end fixing portion 44 is formed mainly by foaming an L-shaped unfoamed resin sheet 400L (FIG. 3) which will be described later.

In the manufacturing process described later, the end fixing portion 44 is also in a restricted section such as between the end surface of the coil 2 (winding portions 2a, 2b) and the inner end surface of the outer core portion (the inner end surface 320e of the outer core component 320). The volume expansion of the above-described foamed resin causes the volume expansion to intervene between the coil 2 and the outer core portion, thereby inhibiting the contact between the two. The end fixing portion 44 regulates the movement of the coil 2 (particularly the movement in the axial direction) by this intervention. The end fixing portion 44 shown in this example can be bonded to both the end surface of the coil 2 and the inner end surface of the outer core portion by the adhesive force of the resin itself in addition to the volume expansion. Contribute to the regulation of

Since the movement of the coil 2 can be sufficiently restricted by the presence of the inner interposition part 40, the number of end fixing parts 44 between the coil 2 and the outer core part, the length along the L-shaped coil facing region (Length along the circumferential direction of the coil 2) and width (length along the width direction of the winding 2w of the coil 2) are not particularly limited. In this example, the width of the end fixing portion 44 is substantially the same as that of the winding 2w, and the length along the coil facing region is substantially equal to the entire length of the coil facing region. In addition, for example, a form in which a plurality of end fixing portions 44 exist along the L-shaped coil facing region, and the end fixing portions 44 are rectangular and exist only in a part of the L-shaped coil facing region. Or a form smaller than the width of the winding 2w. The larger the number of the end fixing portions 44, or the longer the length (the total length in the case of a plurality of end portions) or the wider the width, the larger the bonding area of the end fixing portion 44 with the coil 2 becomes. It is easy to regulate the movement of the coil 2.

The thickness of the end fixing portion 44 is substantially equal to the distance between the end surface of the coil 2 and the inner end surface of the outer core portion (here, the coil facing region of the inner end surface 320e of the outer core component 320). Here, since the coil 2 (winding portions 2a and 2b) is formed by winding the winding 2w in a spiral shape, its end surface is inclined so as to draw a spiral. Therefore, the distance between the end surface of the coil 2 and the inner end surface (coil facing region) of the outer core portion increases or decreases according to the inclination of the end surface of the coil 2. The L-shaped end fixing portion 44 shown in this example also changes (increases or decreases) according to the inclination of the end face of the coil 2 when the thickness is seen along the L-shape. ). The end fixing portion 44 can be provided in an annular shape along the end surface shape of the coil 2. However, since the distance between the end face of the coil 2 and the inner end face of the outer core portion is not uniform as described above, when an annular sheet formed by cutting an unfoamed resin sheet is foamed, locally A part that is greatly inflated and contains a large amount of air bubbles is inferior in strength, which may cause a reduction in fixing strength. Therefore, as shown in this example, it is considered preferable that the end fixing portion 44 exists so as to be in contact with a part of the end surface of the coil 2 in the circumferential direction (here, an L-shaped region).

In this example, between one end portion of the winding portions 2a and 2b and one outer core portion (herein, the outer core component 320, hereinafter the same in this section), and the other end portion and the other outer core portion. L-shaped end fixing portions 44 to 44 exist between each of the two, but the end fixing portion 44 exists only between any one end portion and any one outer core portion. It can be set as a form to do. In this case, the thickness of the end fixing portion 44 is made thicker than that in the case where the end fixing portions 44, 44 are present between both ends of the winding portions 2a, 2b and the outer core portion. Therefore, it is easy to suppress the movement of the coil 2. In this case, the end fixing portion 44 is preferably present between the end portion on the coupling portion 2r side of the coil 2 and one outer core portion. By this end portion fixing portion 44, the end 2 e side of the winding 2 w in the coil 2 is brought into contact with the other outer core portion side and is easily stabilized. As a result, the connection portion between the end 2e of the winding 2w and the terminal fitting is difficult to vibrate, and it is easy to suppress application of excessive stress to the connection portion.

.. Constituent material The coil fixing part 4 is composed of a plurality of bubbles and a resin containing these bubbles, that is, a foamed resin. Since this resin is in contact with the coil 2, it is preferable that the resin has excellent electrical insulation and heat resistance with respect to the highest temperature reached by the coil 2 (150 ° C. or higher, more preferably 180 ° C. or higher). Furthermore, it is preferable that this resin has excellent resistance to a liquid refrigerant that can be contacted. Specific examples of the resin include PPS, nylon, and epoxy resin.

-Manufacturing method Typically, the coil fixing | fixed part 4 can be formed by performing the heat processing required for foaming, after arrange | positioning unfoamed resin in desired positions, such as 3A of magnetic cores. For example, an unfoamed resin sheet is cut into a predetermined shape, and the resin sheets 400 and 400L (FIG. 3) are arranged at a desired position such as the magnetic core 3A, and then subjected to heat treatment necessary for foaming to produce a coil. The fixing part 4 can be formed. When a resin sheet is used, (1) it can be easily cut into a desired shape and size, and since it has excellent flexibility, it can be easily placed at any location and has excellent workability. (2) In a relatively wide range On the other hand, there is an advantage that unfoamed resin can be arranged in a short time. In addition, a liquid resin can be used as an unfoamed resin. The use of a liquid resin has the advantages that (1) the amount of resin can be easily adjusted, and (2) an unfoamed resin can be reliably filled in an arbitrary size and shape such as a relatively narrow portion. The liquid resin is easy to be disposed in a predetermined region, particularly when used in a form having a recess described later. In embodiments and the like to be described later, a manufacturing method using a resin sheet is exemplified, but a liquid resin can be used instead of or in combination with the resin sheet.

The heating temperature and holding time of the heat treatment may be appropriately selected according to the material of the unfoamed resin. For example, the heating temperature is about 100 ° C. or higher and 170 ° C. or lower. Use of a resin having a low heating temperature and a short holding time is preferable because thermal damage to the coil 2 and the magnetic core 3A (particularly, the resin mold portions 310m and 320m) can be prevented during heat treatment. In addition, by using a resin that can be foamed at a low temperature in a short time, the productivity can be improved and the cost can be reduced.

As the unfoamed resin sheet or liquid resin, commercially available products or known ones can be used. For example, it is made of a resin containing capsule particles filled with a liquid, and the liquid is vaporized by heating and the capsule expands to expand the resin. The thickness of the resin after foaming is, for example, 3 times or more of the thickness of the resin before foaming (sheet thickness, filling thickness, etc.), 4.5 times or more, and further 5 times or more. If the expansion coefficient required by (thickness of the resin after foaming / thickness of the resin before foaming) is 3 or more, 4.5 or more, and 5 or more, foaming with the coil 2, the inner core, or the like It is expected that the contact state with the resin can be sufficiently maintained. If the expansion coefficient is too large, it may cause a decrease in strength after foaming as described above because it contains many bubbles. Therefore, it is preferable to select an expansion coefficient according to the size of the gap. As the unfoamed resin, an unfoamed resin sheet including an unfoamed resin layer and an adhesive layer, or a liquid resin containing an adhesive component can be used. When the adhesive layer or the adhesive component is provided, the coil fixing portion 4 (especially the inner interposition portion 40) is used as the inner peripheral surface of the coil 2 (the winding portions 2a and 2b) or the inner core portion of the magnetic core 3A ( Here, the coil 2 can be firmly bonded to the outer peripheral surface of the inner core component 310A), and the coil 2 can be firmly fixed. Further, when the adhesive layer is provided, even when the unfoamed resin layer is thin, the coil fixing portion 4 having a desired thickness is obtained by bonding and laminating a plurality of resin sheets with the adhesive layer. Can be formed. The thickness of the unfoamed resin, specifically the thickness of the sheet (including the thickness of the adhesive layer if an adhesive layer is provided) and the filling thickness are the thickness after foaming of the coil 2 and the inner core. It is good to select according to an expansion coefficient etc. so that it may become more than the distance between parts, and more than the said distance. For example, if the thickness of the unfoamed resin sheet is 0.2 mm or more and the expansion coefficient is 4, the average thickness 4t (thickness after foaming) of the inner interposition part 40 is 0.8 mm or more. . In the following drawings, the sheets 400, 400L, 400П, 400Γ, 400￢, 400 [, 400] are shown thick for easy understanding.

(Reactor manufacturing method)
An example of a method for manufacturing the reactor 1A will be described with reference mainly to FIG.
First, the inner core parts 310A and 310A and the outer core parts 320 and 320 are manufactured and prepared by insert molding or the like. A coil 2 is manufactured and prepared by winding the winding 2w edgewise.

Next, each inner core part 310A, 310A and one outer core part 320 are connected to form a U-shaped intermediate part, and the inner core parts 310A, 310A are placed in the winding portions 2a, 2b of the coil 2. Are inserted and arranged. In this state, the coil 2 is supported slidably in the axial direction with respect to the inner core components 310A and 310A, and is not fixed. In this state, the unfoamed resin sheet 400 is inserted into the inner circumferential space between the inner circumferential surfaces of the winding portions 2a and 2b and the outer circumferential surfaces of the inner core components 310A and 310A. The unfoamed resin sheet 400 is sufficiently thinner than the inner peripheral space and can be easily disposed. In this example, a non-foamed resin sheet 400 cut into a rectangular shape is prepared corresponding to the upper and lower rectangular planes at the opposing positions in the inner core component 310A. These sheets 400 and 400 are respectively inserted into the upper and lower spaces at opposite positions in the inner circumferential space. Next, each inner core component 310A, 310A and the other outer core component 320 are connected to form an annular magnetic core 3A. The end surfaces 310e and 310e of the inner core components 310A and 310A may be joined to the inner end surface of the outer core component 320 (the inner end surface 32e of the side main body portion 32) with an adhesive or the like.

Next, in this example, an unfoamed resin sheet 400L cut into an L-shape is also prepared, and the sheet 400L is prepared from the end surfaces of the winding portions 2a and 2b and the inner end surfaces 320e of the outer core components 320 and 320, respectively. It is inserted between the coil facing region at 320e. As described above, since the distance between the end surfaces of the winding portions 2a and 2b and the inner end surface 320e of the outer core component 320 is not uniform, a part of the sheet 400L is sandwiched between the short distances and the narrow intervals. Thus, the sheet 400L can be prevented from falling off to some extent. In addition, at the time of foaming, the lower side of the L-shaped sheet 400L is supported by a mounting surface of a heat treatment apparatus for foaming, and thus the sheet 400L can be prevented from dropping to some extent.

If the resin sheet 400, 400L, etc. before heat treatment is in a semi-cured state or the like and has a certain degree of adhesiveness, the sheet 400 is affixed to the inner core component 310A and temporarily fixed in the winding parts 2a, 2b. Or the coil 2 and the inner core components 310A and 310A can be assembled in a state where the sheet 400L is pasted and temporarily fixed to the outer core component 320. In this case, the number of processes can be reduced and the assembly workability is excellent. In addition, since the sheets 400 and 400L can be adhered to the winding portions 2a and 2b and the core components 310A and 320 to some extent even during the period from heat treatment to foaming, the sheets 400 and 400L can be more easily prevented from falling off.

The combination 10 of the coil 2 and the magnetic core 3A including the unfoamed resin sheets 400 and 400L is subjected to heat treatment to foam the sheets 400 and 400L. The resin formed by foaming the sheet 400 is disposed in an inner circumferential space (here, a part in the circumferential direction and the entire length in the axial direction) between the coil 2 and the inner core portion, and the winding portions 2a and 2b. The inner interposition part 40 and the turn interposition part 42 are formed in close contact with the inner peripheral surface and the inner core part. The resin formed by foaming the sheet 400 </ b> L is in close contact with the end surface of the coil 2 and the end surface of the outer core portion to form the end fixing portion 44. A part of the sheet 400 may be interposed between the end face of the coil 2 and the inner end face 320e of the outer core component 320 to form the end fixing portion 44. By this step, the reactor 1A including the coil fixing portion 4 is obtained.

(Effects based on main features)
The reactor 1A of the first embodiment includes a coil fixing portion 4, and a gap between the coil 2 and the inner core portion or a gap between the turns 2t and 2t due to the volume expansion of the foamed resin constituting the coil fixing portion 4. And the movement of the coil 2 can be regulated by being interposed in these gaps. In particular, the coil fixing portion 4 is formed from the inner peripheral side of the coil 2 by the inner interposed portion 40 interposed between the inner peripheral surface of the coil 2 and the outer peripheral surface of the inner core portion (here, the inner core component 310A). Regulate the movement of 2. Furthermore, the adhesive force of the foamed resin itself also contributes to the regulation of the movement of the coil 2. In addition, a pressing force may be generated in the foamed resin depending on the arrangement state and expansion amount of the foamed resin, and this pressing force is also expected to contribute to the regulation of the movement of the coil 2. Even if such a reactor 1A is not provided with a sealing material that integrally covers the outer periphery of the combined body 10 including the coil 2 and the magnetic core 3A, the vibration of the coil 2 during the operation of the reactor 1A and the magnetic core 3A The movement of the coil 2 in the axial direction, the radial direction, and the circumferential direction with respect to the inner core portion can be restricted by vibration, the influence of the external environment (for example, circulation of the liquid refrigerant), and the like. Since the movement of the coil 2 can be restricted, the reactor 1A can cause the coil 2 to rub or collide with the magnetic core 3A (the inner core component 310A and the outer core component 320), or the adjacent turns 2t and 2t of the coil 2 can rub against each other. It is possible to suppress a collision. Therefore, the reactor 1A can reduce, and preferably prevent, noise caused by the rubbing and collision, damage to the insulation coating of the coil 2, damage to the magnetic core 3A, and the like.

In particular, in the reactor 1A shown in this example, the inner interposition portion 40 of the coil fixing portion 4 is provided over the entire length of the inner core portion, and is present at a facing position between the coil 2 and the inner core portion. In addition, by providing the end fixing portion 44, the movement of the coil 2 can be more reliably regulated. The presence of the coil fixing portion 4 at the facing position makes it difficult for the inner core portion to be unevenly distributed in the coil 2. The deviation of the position of the coil 2 with respect to the inner core portion can be reduced by the foamed resin at the facing position, and the position of the coil 2 with respect to the inner core portion can be accurately determined. Specifically, the central axes of the coil 2 and the inner core portion can be aligned. Further, in the reactor 1A shown in this example, the inner interposition part 40 of the coil fixing part 4 is present only in a part in the circumferential direction with respect to the cylindrical inner peripheral space between the coil 2 and the inner core part. For this reason, when the cooling structure using the liquid refrigerant is used, the liquid refrigerant easily flows and the heat dissipation is improved. Furthermore, since the turn interposition part 42 has a size that does not reach the outer peripheral surface of the coil 2, the contact area between the coil 2 and the liquid refrigerant is increased, and the heat dissipation is further improved.

Furthermore, since the reactor 1A of Embodiment 1 does not include the above-described sealing material, the case of filling the sealing material can be omitted, and the process of filling, solidifying and curing the sealing material in addition to being small in size. And the productivity of the reactor 1A can be improved.

Furthermore, the reactor 1A of the first embodiment does not use a molded member such as a bobbin manufactured to have a predetermined thickness for regulating the movement of the coil 2, but foams an unfoamed resin sheet. The formed coil fixing part 4 is used. In other words, the reactor 1 </ b> A forms a coil fixing portion 4 that serves as a movement restricting portion of the coil 2 by using a reactor whose thickness increases in the manufacturing process. Therefore, the thickness of the coil fixing portion 4 can be easily reduced and the distance between the coil and the core can be shortened as compared with the case where an independent molded member whose thickness is not changed is used. Also from this point, the reactor 1A can be downsized. Further, the reactor 1A can reduce the number of parts to be assembled and the number of processes by omitting a molded member, and the productivity can be improved. In addition, the reactor 1A is reduced in size because the coil fixing portion 4 is provided in contact with the middle resin mold portion 310m and the middle main body portion 31 of the magnetic core 3 is mainly formed of a compacted body. Can be planned.

(Configuration details etc.)
Hereinafter, the details of each configuration of the reactor 1A, other available configurations, etc. will be listed and described.

-Coil The winding parts 2a and 2b of the coil 2 have the same number of turns and are electrically connected in series. The end surface shapes of the winding portions 2a and 2b can be changed as appropriate, such as an annular shape, in addition to the above-described rectangular tube shape. In addition to forming the coil 2 with one continuous winding 2w having no connection part, each winding part is produced by separate windings, and the other ends of the windings of each winding part are welded, soldered, or crimped. It can be set as the coil joined directly via the connection member (for example, board | plate material) prepared separately, for example by the coil directly joined by.

As the winding 2w, a coated wire including a conductor and an insulating coating can be suitably used. Examples of the constituent material of the conductor include metals having excellent conductivity such as copper, copper alloy, aluminum, and aluminum alloy. Examples of the conductor include a flat wire and a round wire. When an edgewise coil is formed using a winding whose conductor is a flat wire as in the first embodiment, the space factor can be increased more easily than in the case where a round wire is used, and the size can be reduced. Examples of the constituent material of the insulating coating include insulating materials such as polyamideimide.

The pulling direction of the end 2e of the winding 2w constituting the coil 2 can be selected as appropriate. In the first embodiment, as shown in FIG. 1, the winding 2 w is flatwise bent in the upper region of the end face of the coil 2, and the end 2 e of the winding 2 w is pulled out parallel to the axial direction of the coil 2. Yes. By this drawing direction, the size of the reactor 1A in the vertical direction can be reduced as compared with the case where the end 2e of the winding 2w is drawn above the outer peripheral surface of the coil 2 (see FIG. 7 and the like described later).

-Magnetic core-Inner core part 310 A of inner core parts which comprise an inner core part are the middle main-body part 31 by which the core piece 31m and the gap material 31g were laminated | stacked alternately, and the whole outer peripheral surface of the middle main-body part 31 And a middle resin mold part 310m for covering.

The core piece 31m made of a compacted body typically includes a soft magnetic material such as a metal such as iron or an iron alloy (Fe—Si alloy, Fe—Ni alloy, etc.), a non-metal such as ferrite, and an appropriate binder (resin). Etc.) and a lubricant, and then heat treatment for the purpose of removing distortion associated with the molding is obtained. Since the binder and the lubricant are typically lost by this heat treatment, it is easy to obtain a compact with a higher saturation magnetic flux density and relative magnetic permeability than the composite material described later.

As a constituent material of the gap material 31g, a nonmagnetic material such as alumina or unsaturated polyester, a mixture containing a nonmagnetic material such as PPS resin and a soft magnetic material (eg, soft magnetic powder such as iron powder), or the like can be used. . The core piece 31m and the gap material 31g may be fixed with an adhesive or an adhesive tape.

The middle resin mold part 310m in this example covers both end faces 31e and 31e (FIG. 3) of the middle main body part 31, and the covering resin of each end face 31e and 31e functions as a gap material. The covering area of the middle main body part 31 in the middle resin mold part 310m and the covering area of the side main body part 32 in the side resin mold part 320m described later can be appropriately changed. For example, a form in which a part of the middle main body part 31 is exposed from the middle resin mold part 310m, a form in which the entire outer peripheral surface of the side main body part 32 is covered with the side resin mold part 320m, and the like can be used. The thickness of the middle resin mold part 310m and the thickness of the side resin mold part 320m described later can also be selected as appropriate. As the covering area of the middle resin mold part 310m is larger or thicker, the insulation between the coil 2 and the middle main body part 31 is improved, and as the thickness is thinner, the coil 2 and the middle main body part 31 The distance between the two can be reduced, and downsizing can be achieved. As the covering area of the side resin mold part 320m is larger or thicker, the insulation between the coil 2 or the terminal fitting and the side main body part 32 can be improved. Further, the larger the coating area of the resin mold portions 310m and 320m or the thicker the thickness, the more the body portions 31 and 32 can be protected from the external environment and mechanical protection can be achieved. The average thickness of the resin mold parts 310m and 320m is 0.1 mm or more and 3 mm or less, further 2.5 mm or less, and further 2 mm or less.

In this example, in the middle resin mold part 310m of the inner core part 310A, the thickness in the vicinity of the end face of the part covering the peripheral surface of the middle main body part 31 is thin. A cylindrical portion that protrudes from an inner end surface 320e of the outer core component 320 described later is fitted into the thin region. The thin portion and the cylindrical portion function as an engaging portion between the core components 310A and 320, and the inner core component 310A and the outer core component 320 are mechanically connected by the engaging portion.

-Outer core part The outer core part 320 which comprises an outer core part is provided with the side main-body part 32 and the side resin mold part 320m which covers the whole substantially except for a part of side main-body part 32. FIG.

The side main body 32 is a core piece 32m made of a compacted body. In this example, the side main body portion 32 has a dome shape on the upper surface and the lower surface (a deformed trapezoidal shape whose sectional area decreases outwardly from the inner end surface 32e to which the end surface 310e of the inner core component 310A is connected). The shape of the side main body 32 can be selected as appropriate. In this example, the side resin mold part 320m exposes a part of the inner end face 32e of the side main body part 32 (core connection region to which the inner core components 310A and 310A are connected) and covers the remaining part. In this example, side resin mold part 320m is provided with a cylinder part projected from inner end face 320e as mentioned above.

In addition, the side resin mold part 320m has the following configuration.
A mounting portion 325 (FIGS. 1 to 3) for attaching the reactor 1A to the installation target. In this example, the attachment portion 325 is a protruding piece that protrudes outward, and includes a bolt hole 325h to which a bolt for fixing the reactor 1A is attached to the installation target. A total of four attachment portions 325 to 325 are provided for each of the outer core components 320, two in total for the reactor 1A.
A plate-shaped partition 327 (FIG. 3) interposed between the winding parts 2a and 2b. In this example, a part of the partition part 327 also supports a sensor holding part 75 described later.
At least one of the engaging part, the attaching part 325, and the partition part 327 of both the core components 310A and 320 described above can be omitted. You may make the thickness of resin which comprises these thicker than another part.

.. Constituent material of resin mold portion As a constituent material of the middle resin mold portion 310m and the side resin mold portion 320m, an appropriate resin can be used. In particular, since it is arranged in the vicinity of the coil 2, a resin having electrical insulation, heat resistance, resistance to a liquid refrigerant and the like is preferable, and a resin excellent in thermal conductivity is more preferable. Specific resins include PPS resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin such as nylon 6, nylon 66, nylon 10T, nylon 9T, and nylon 6T, polybutylene terephthalate ( Thermoplastic resins such as PBT resin and acrylonitrile butadiene styrene (ABS) resin. Examples of other resins include thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins. The resin contains a filler made of ceramics such as silicon nitride (Si ₃ N ₄ ), alumina (Al ₂ O ₃ ), aluminum nitride (AlN), boron nitride (BN), silicon carbide (SiC), mullite. May be. If the resin contains one or more of the listed ceramic fillers, the heat dissipation and insulation of the resin mold parts 310m and 320m can be improved. Depending on the filler composition, vibration and noise suppression effects can also be expected.

-Usage example As one usage example of the reactor 1A, the combination 10 including the coil 2 and the magnetic core 3A shown in Fig. 1 is housed in a cooling case (not shown) to which a liquid refrigerant is supplied, and the liquid refrigerant is used. It can be set as the form to cool. In particular, it is preferable that the liquid refrigerant is supplied and circulated. When the reactor 1A is used in a vehicle, the liquid refrigerant does not need to be separately prepared by diverting the lubricating oil of an automatic transmission. In this usage example, when the coil 2 is not covered with the sealing material so that the coil 2 can directly contact the liquid refrigerant, a high cooling effect by the liquid refrigerant can be expected. The coil 2 can suppress the movement caused by the flow of the liquid refrigerant circulated and supplied by the coil fixing portion 4, and can suppress the above-mentioned rubbing and collision, noise and damage caused by them.

-Other equipment member In addition, 1 A of reactors can be equipped with the following members. At least one of these members can be omitted. These members can be provided or omitted as appropriate for the later-described embodiments and modifications.

.. Sensor Reactor 1A can be configured to include a sensor that measures a physical quantity, such as a temperature sensor, a current sensor, a voltage sensor, or a magnetic flux sensor. In this example, the sensor 7 (FIGS. 2 and 3) includes a temperature sensor including a thermal element such as a thermistor. In this example, the sensor 7 is held by a flat sensor holding portion 75. A part of the sensor holding part 75 is engaged with the partition part 327 described above, and is held by the reactor 1A. As the constituent material of the sensor holding portion 75, the same resin as the constituent material of the middle resin mold portion 310m can be used.

.. Heat radiation plate The reactor 1A can be configured to include a heat radiation plate (not shown) at an arbitrary location on the outer peripheral surface of the coil 2. For example, if the installation surface (here, the lower surface) of the coil 2 is provided with a heat radiating plate, the heat of the coil 2 can be transmitted well to the installation target via the heat radiating plate, and the heat dissipation can be improved. As the constituent material of the heat sink, a material having excellent thermal conductivity such as a metal such as aluminum or an alloy thereof, or a non-metal such as the above-described ceramic can be used. You may provide a heat sink in the whole installation surface (here lower surface) of 1 A of reactors. The heat sink can be fixed by, for example, a bonding layer described later. Reactor 1A can be configured to include a heat sink and a bonding layer.

..Junction layer Reactor 1A can be made into the form provided with a joining layer (not shown) in the installation surface (here lower surface) of the coil 2 at least among the installation surfaces (here lower surface). By providing the bonding layer, the coil 2 can be firmly fixed to the heat sink when the installation target or the above-described heat dissipation plate is provided, thereby improving heat dissipation, stability of fixing to the installation target or the heat dissipation plate, and the like. be able to. Furthermore, the reactor 1 </ b> A can regulate the movement of the coil 2 not only by the coil fixing portion 4 but also by a bonding layer. Since the constituent material of the bonding layer is in contact with the coil 2, an insulating resin is preferable. Further, the constituent material of the bonding layer contains the above-mentioned ceramic filler and the like and has excellent heat dissipation, for example, thermal conductivity is 0.1 W / m · K or more, further 1 W / m · K or more, particularly 2 W / The thing more than m * K is more preferable. Specific examples of the resin include thermosetting resins such as epoxy resin, silicone resin, and unsaturated polyester, and thermoplastic resins such as PPS resin and LCP. Prior to installation, a release material or the like may be attached to the bonding layer.

[Modification 1-1]
In the first embodiment, the mode in which the coil fixing portion 4 exists at the opposing position in the cylindrical inner circumferential space between the coil 2 and the inner core portion has been described. In addition, it can be set as the form containing the coil fixing | fixed part 4 which is not provided in the said opposing position. For example, providing the coil fixing | fixed part 4 in at least 1 area | region of an upper side area | region, a lower side area | region, a left side area | region, and a right side area | region in the said inner peripheral space is mentioned. This form is preferable when the foamed resin has sufficient adhesive force. Or this form is preferable when providing the above-mentioned joining layer. This is because, as described above, the installation surface (lower surface) of the coil 2 and its vicinity can be fixed by the bonding layer, and regulation of the movement of the coil 2 by the bonding layer can be expected. In this case, for example, the coil fixing portion 4 may be provided in at least one of the upper region, the left region, and the right region of the inner circumferential space. The configuration of Modification 1-1 can be applied to Embodiments 2-1, 2-2, 3 to 8 described later, or in combination with Embodiments 9 to 13.

[Modification 1-2]
In the first embodiment, the form in which the magnetic core 3A includes four core parts (two inner core parts 310A and 310A and two outer core parts 320 and 320) has been described. In addition, one middle main body part 31 and one side main body part 32 are assembled in an L shape and are provided with a set of L-shaped core parts integrally held in the resin mold part, that is, a total of two magnetic cores 3A. Of the L-shaped core part, two U-shaped core parts 31 and 31 and one side main body part 32 assembled in a U shape and integrally held in the resin mold part, and one In other words, the magnetic core 3A includes a total of two core components.

[Embodiment 2-1]
A reactor 1B according to Embodiment 2-1 will be described with reference to FIGS. 4, FIG. 10, FIG. 13, FIG. 19, and FIG. 22 to be described later, a part of one winding part 2a of the coil 2 or the winding of the coil 2F so that the inner core part and the coil fixing part 4 can be easily understood. The part 2c and a part of the coil fixing part 4 are cut out.

(Reactor)
Overall Configuration In the first embodiment described above, the outer peripheral surface of the middle resin mold part 310m of the inner core component 310A is uniform, and the thickness of the resin mold part 310m is substantially uniform. The form which the coil fixing | fixed part 4 contacts was demonstrated. In the reactor 1B of the embodiment 2-1, the concave portion 310r is provided in the middle resin mold portion 310m covering the middle main body portion, and a part of the foamed resin constituting the coil fixing portion 4 is disposed in the concave portion 310r. Is one of the differences from the first embodiment. In addition, the reactor 1B of the embodiment 2-1 is different from that of the first embodiment in the shape, formation time, and the like of the middle resin mold portion 310m and the side resin mold portion 320m. The following description will be made in detail with a focus on differences from the first embodiment, and detailed description of overlapping configurations and effects will be omitted.

Magnetic core reactor 1B is an inner core portion of a magnetic core 3B, as shown in FIG. 5, a middle main body portion including a core piece 31m and a part of a middle resin mold portion 310m covering the middle main body portion (mainly described later core An inner core component 310B including a covering portion). As the outer core portion, a side main body portion 32 including a core piece 32m, a side resin mold portion 320m (FIG. 4) covering the side main body portion 32, and another portion (mainly, a frame portion 315 described later) of the middle resin mold portion 310m. Is provided. The magnetic core 3B is assembled with a pair of side main body portions 32, 32 so as to connect a pair of inner core components 310B, 310B (middle main body portions) arranged side by side, and covers the side main body portions 32, 32 in this state. The side resin mold parts 320m and 320m are molded into a molded product fixed as an annular body. The reactor 1B uses the side main body 32 as one of the assembly parts in the manufacturing process.

The middle resin mold part 310m provided in each inner core part 310B, 310B is a core covering part provided so as to cover the entire outer periphery along its outer shape in a state where a plurality of core pieces 31m,... Are arranged at equal intervals. And a frame portion 315 interposed between the end surfaces of the winding portions 2a and 2b of the coil 2 and the inner end surface 32e of the side main body portion 32 (core piece 32m). Each inner core component 310B, 310B is an L-shaped molded body with the above-described core covering portion and frame portion 315. In this example, the end surface 31e of the core piece 31m located at one end of the inner core component 310B is exposed without being covered with the resin mold portion 310m. Moreover, the resin mold part 310m has the gap part 310g interposed between the adjacent core pieces 31m and 31m. The end face of the core piece 31m located at the other end of the inner core component 310B is covered with the resin mold part 310m as in the first embodiment, and this resin functions as a gap material.

.. Recessed portion The inner core component 310B includes a recessed portion 310r in the core covering portion. In this example, the upper and lower opposing surfaces and the left and right opposing surfaces in the core covering portion are each provided with a recess 310r. Each inner core component 310B includes a total of four recesses 310r.

The concave portion 310r functions as a filling portion in the manufacturing process of the reactor 1B, for example, when positioning and storing the unfoamed resin sheet 400, or using an unfoamed liquid resin. In the reactor 1B, the concave portion 310r is a region where a part of the foamed resin constituting the coil fixing portion 4 is disposed. In order to satisfactorily perform the above-described function, it is preferable that the reactor 1 </ b> B includes the concave portions 310 r corresponding to the number of the coil fixing portions 4. Moreover, in order to fully exhibit the above-mentioned function, (i) the concave portion 310r is provided corresponding to the position where the coil fixing portion 4 is formed, and when the sheet 400 is used, (ii) the cross-sectional shape of the sheet 400, Corresponding to a planar shape (typically, the cross-sectional shape and planar shape of the recess 310r are rectangular as shown in FIG. 5), and (iii) the depth of the recess 310r is equal to or greater than the thickness of the sheet 400. (Iv) It is preferable that the length and width of the recess 310r are equal to or greater than the length and width of the sheet 400.

When using an unfoamed liquid resin, the depth, length, and width of the recess 310r may be selected in consideration of the expansion coefficient. Since the maximum filling amount of the unfoamed liquid resin is equal to or less than the depth of the recess 310r, the above-mentioned rubbing hardly occurs or does not substantially occur. Since the unfoamed liquid resin can be adapted to a recess having an arbitrary size and shape, for example, the recess 310r can be a stepped groove or a tapered groove. Depending on the formation position of the recess 310r, when there is a possibility that the liquid resin may flow out of the recess 310r due to its own weight, it is preferable to use the unfoamed resin sheet 400. When the unfoamed liquid resin is difficult to flow out because it contains an adhesive component or the like, the liquid resin can be filled into the recess 310r provided at an arbitrary position (see embodiment 2-2 described later). ). When there is a partially deep portion in the recess 310r, a plurality of unfoamed resin sheets 400 may be stacked and arranged as described above according to the depth of the deep portion.

Regarding (iii) above, if the depth of the recess 310r is equal to or greater than the thickness of the unfoamed sheet 400, when the sheet 400 is stored in the recess 310r, one surface of the sheet 400 does not protrude from the recess 310r. Therefore, when the coil 2 and the inner core component 310B are assembled, the coil 2 and the sheet 400 can be prevented from rubbing and the sheet 400 can be prevented from being displaced or dropped off, and the assembly workability is excellent. In particular, even when the sheet 400 has a certain degree of tackiness as described above or includes an adhesive layer, the above-described rubbing does not occur, so the sheet 400 stored in the recess 310r is displaced or peeled off. Excellent assembly workability. The depth of the recess 310r is, for example, about 100% or more and 130% or less of the thickness of the sheet 400, and further about 100% or more and 120% or less. For example, in the sheet 400 having a thickness of 0.2 mm, it is considered that the above-described function can be sufficiently achieved if the depth of the recess 310 r is about 0.25 mm. The specific depth is, for example, about 0.1 mm or more and 0.4 mm or less. In order to deepen the concave portion 310r, it is necessary to increase the thickness of the middle resin mold portion 310m, which increases the distance between the coil and the core. As a result, the reactor 1B is increased in size. Further, if the recess 310r is too deep, it is necessary to use a sheet 400 having a sufficiently large expansion coefficient. The sheet 400 having a large expansion coefficient has a large number of bubbles as described above, and there is a possibility that the fixing strength of the coil 2 may be insufficient due to a decrease in the strength of the foamed resin. From these points, it is considered that the depth of the recess 310r is preferably in the above range.

Regarding (iv) above, if the length and width of the recess 310r are approximately the same as the length and width of the unfoamed sheet 400, the positioning of the sheet 400 can be performed with high accuracy and workability is excellent. Furthermore, since the coil fixing part 4 in the reactor 1B is positioned with high accuracy, the coil 2 can be fixed easily. If the length and width of the recess 310r satisfy at least one of the length and width exceeding the sheet 400, the sheet 400 can be easily disposed.

In this example, the depth, length, and width of the recess 310r are set to be approximately the same as the thickness, length, and width of the unfoamed sheet 400. Therefore, a part of the foamed resin that constitutes the coil fixing part 4 provided in the reactor 1B is disposed in the recess 310r, and another part leaks from the recess 310r and the inner peripheral surface of the coil 2 (winding parts 2a, 2b). Between the outer peripheral surface of the core covering portion of the middle resin mold portion 310m and the portion excluding the concave portion 310r, and another portion forms a turn interposition portion (not shown).

-Coil fixing part Reactor 1B is foamed resin in a total of four places of the up-and-down opposing position and the right-and-left opposing position in the cylindrical inner peripheral space between the coil 2 and the inner core part as in the first embodiment. The coil fixing part 4 comprised from these is provided. In Embodiment 2-1, the length along the axial direction of the inner circumferential space in the inner interposition part 40 (FIG. 1) is about 80%, and the length along the circumferential direction is the circumferential direction of the inner circumferential space. About 40% of the length, and exists only in a part of the circumferential direction. The embodiment 2-1 and the embodiments 2-2 and 3 to 13 described later do not include the end fixing portion 44 (FIG. 1 and the like), but can be provided similarly to the embodiment 1.

(Reactor manufacturing method)
With reference mainly to FIG. 5, an example of the manufacturing method of the reactor 1B is demonstrated.
First, a plurality of core pieces 31m are spaced apart and covered with a middle resin mold part 310m, and the resin is also filled between the core pieces 31m and 31m, and an inner core having a gap part 310g, a frame part 315, and a concave part 310r is provided. Parts 310B and 310B are prepared. The side main body 32 and the coil 2 are prepared.

Next, in this example, an unfoamed resin sheet 400 is disposed in the recess 310r of each inner core component 310B, 310B. It is preferable that the sheet 400 has a certain degree of tackiness or has an adhesive layer so as not to drop off from the arranged recess 310r.

Next, the inner core portions (core covering portions) of the inner core components 310B and 310B including the unfoamed resin sheet 400 are inserted into the winding portions 2a and 2b of the coil 2, respectively. Heating is performed in this state, the resin sheet 400 is foamed to form the coil fixing portion 4, and the coil 2 and the inner core component 310B are fixed.

Next, the side main body portions 32 and 32 are arranged so as to sandwich the frame portions 315 and 315, and assembled in an annular shape to produce a braid. Reactor 1B is obtained by covering and solidifying the exposed portions of side body portions 32, 32 of this assembly with the constituent resin (unsolidified) of side resin mold portion 320m.

(Effects based on main features)
Since the reactor 1B according to the embodiment 2-1 includes the coil fixing portion 4 made of foamed resin, the inner core portion can be formed during the operation of the reactor 1B even when the reactor 1B is not operated, as in the first embodiment. In contrast, the movement of the coil 2 in the axial direction, radial direction, and circumferential direction can be restricted. Therefore, the reactor 1B can also reduce noise caused by rubbing or collision between the turns of the coil 2 or between the coil 2 and the magnetic core 3B, damage to the insulation coating of the coil 2, and the like.

In particular, the reactor 1B shown in this example is provided with the concave portion 310r in the middle resin mold portion 310m, and therefore is excellent in assembling workability and excellent in productivity from the following points.
The point where the concave portion 310r can be used for positioning and storage of the unfoamed resin sheet 400 and the filling portion of the liquid resin. By adjusting the depth of the concave portion 310r, the coil 2 and the inner core portion (inner core component 310B) It is difficult for the unfoamed resin sheet 400 to be displaced or to be peeled off or dropped from the inner core component 310B when assembled.

In particular, even when there is a dimensional tolerance in the coil 2 and the middle resin mold part 310m, and the gap between the coil 2 and the inner core part is narrow, the coil 2 and the unfoamed resin stored in the recess 310r are not easily rubbed. . Therefore, the reactor 1B is excellent in assembling workability and can increase the tolerance of the tolerance range error. In addition, it is not necessary to widen the interval in order to avoid the rubbing. From this point, the distance between the coil and the core can be shortened, and the reactor 1B can be downsized. When the interval is wide, it is necessary to use a resin having a sufficiently large expansion rate, and as described above, the fixing strength of the coil 2 may be insufficient due to an increase in bubbles. The reactor 1B having a short distance between the coil and the core can use a resin having a low expansion coefficient, so that a predetermined expansion amount can be stably obtained, and a high strength is excellent and stable with respect to the fixing of the coil 2. Is obtained. In addition, since the unfoamed resin (sheet 400) is positioned by the concave portion 310r, not only the manufacturing process but also the coil fixing portion 4 after foaming is accurately positioned, and the reactor 1B stably stabilizes the coil 2. Can be fixed.

(Other features)
Hereinafter, other configurations of the resin mold portions 310m and 320m of the reactor 1B will be described.
.. Middle Resin Mold Part In the L-shaped inner core parts 310B and 310B, the middle resin mold part 310m is molded so that the inner core part of one core part 310B can be assembled to the other frame part 315. The frame portion 315 is covered with a through hole 315h into which an end portion of one inner core portion (a columnar body mainly composed of the core piece 31m and the gap portion 310g) is inserted, and a core covering portion continuous with the frame portion 315. The core piece 31m is provided with an end face portion that covers a part of the end face 31e of the core piece 31m located at the end. One surface of the frame portion 315 is disposed opposite to the inner end surface 32e of the side main body portion 32 (core piece 32m), and the side resin mold portion 320m is joined thereto. The other surface of the frame portion 315 is a plane provided so as to be orthogonal to the axial direction of the winding portions 2a and 2b of the coil 2, and is disposed opposite to the winding portions 2a and 2b (FIG. 4).

The opposite surface (one surface) of the frame portion 315 to the side main body portion 32 includes the following.
A pair of upper and lower ridges 3150 (FIG. 5) for positioning the side main body 32, and a pair of flat plate portions extending from the ridge 3150 and arranged in parallel to the upper and lower surfaces of the side main body 32 3154 (FIGS. 4 and 5)
A plurality of rectangular protruding plate portions 3152 (FIG. 5) for forming a gap between the frame portion 315 and the inner end surface 32e of the side main body portion 32 for promoting introduction of the constituent resin of the side resin mold portion 320m.
A locking portion (a part of the protrusion 3150 having an L-shaped cross section) having a function of increasing the bonding strength with the inner core component 310B by entering the constituent resin of the resin mold portion 320m.

The surface (other surface) facing the coil 2 in the frame portion 315 includes the following.
-Partition plate 3156 interposed between the winding portions 2a, 2b (FIG. 5)
A short cylindrical portion 3158 (FIG. 5) into which the thin region at the end of the core covering portion of the inner core component 310B is fitted.

Furthermore, the inner core component 310B of this example protrudes from the end surface inserted through the through hole 315h in the inner core portion, and protrudes from the through hole 315h when the core components 310B and 310B are assembled, and finally the side resin mold. The rib 3159 covered with the part 320m is provided (FIG. 5). The rib 3159 made of the constituent resin of the middle resin mold part 310m is covered with the side resin mold part 320m, so that the inner core parts 310B and 310B and the side main body parts 32 and 32 are firmly integrated by the side resin mold part 320m. Can be In addition, the rib 3159 can be used as a guide for inserting the core covering portion of the other inner core component 310B into the through hole 315h of the frame portion 315 provided in the one inner core component 310B, and the assembly workability is excellent.

At least one of the protrusion 3150 and the flat plate portion 3154, the rectangular protruding plate portion 3152, the locking portion, the partition plate 3156, the cylindrical portion 3158, the rib 3159, and the mounting portion 325 described later can be omitted.

-Side resin mold part The side resin mold part 320m with which an outer core part is equipped has a core coating | coated part which covers the outer peripheral surface of the side main-body part 32 (core piece 32m). In addition, the resin mold part 320m has a gap part (not shown) that fills the gap between the core pieces 31m and 32m and functions as a gap. In addition, the resin mold part 320m is provided with the attachment part 325 similarly to Embodiment 1 (FIG. 5).

The resin mold portions 310m and 320m provided in the reactor 1B are formed by covering the core pieces 31m and 32m, forming the inner core portion (joining the core pieces 31m and 31m), and joining the inner core portion and the outer core portion (core piece 31m). , 32m) and the formation of a gap such as the gap portion 310g. In addition, it can replace with the gap by the constituent resin of resin mold part 310m, 320m, and can be set as the form provided with a gap material like Embodiment 1, the form provided with another air gap, or the form which does not have a gap.

[Embodiment 2-2]
Hereinafter, the reactor 1b of the embodiment 2-2 will be described with reference to FIG. The basic configuration of the reactor 1b of the embodiment 2-2 is the same as that of the reactor 1B of the embodiment 2-1. The magnetic core 3b includes the following inner core portion and outer core portion. The inner core portion includes a middle main body portion including the core piece 31m and a middle resin mold portion 310m that covers a part of the outer peripheral surface of the middle main body portion. Further, in this example, the inner core portion is made of a constituent resin of the middle resin mold portion 310m. A gap portion 310g. The outer core portion includes a side main body portion 32 made of a core piece 32 m and a side resin mold portion 320 m that covers the side main body portion 32. The reactor 1b is one of the differences from the embodiment 2-1 in that the inner core portion includes a specific recess 312r. Hereinafter, this difference will be described in more detail. In FIG. 6, the turn interposition part is omitted.

As described in the embodiment 2-1, the thickness of the middle resin mold part 310m can be partially changed so that the thin part can be used as the arrangement position of the coil fixing part 4. In the reactor 1b, the resin component of the resin mold part 310m is not partially present, and a region where a part of the outer peripheral surface of the middle main body part is exposed is provided, and a recess formed by the exposed region and the resin mold part 310m is provided. This recess is used in the same manner as the above-described recess 310r. This recess has an exposed portion of the middle body portion (core piece 31m) that is not covered with the resin mold portion 310m as a bottom portion, and an inner wall portion made of a constituent resin of the resin mold portion 310m formed so as to surround the exposed portion. The bottomed hole 3120 is provided. The resin mold part 310m of this example is further provided with a groove part 3122. The groove part 3122 is formed by a groove bottom part and an inner wall part made of a constituent resin of the resin mold part 310m. The opening edge of the bottomed hole 3120 is continuous with the groove bottom (bottom surface). The recess 312 r includes the bottomed hole 3120 and the groove 3122, and forms a space continuous from the bottomed hole 3120 to the groove 3122.

In FIG. 6, in the inner circumferential space provided between the winding portions 2a and 2b of the coil 2 and the inner core portion disposed therein, the upper region and the lower region are respectively provided with recesses 312r and 312r. Show. FIG. 6 illustrates an example in which each recess 312 r includes a plurality of bottomed holes 3120 and the size of the opening of the groove 3122 is sufficiently larger than the size of the opening of each bottomed hole 3120. Further, FIG. 6 shows an example in which a bottomed hole 3120 is provided for each core piece 31m. The inner core portion including the concave portion 312r including the bottomed hole 3120 and the groove portion 3122 can be obtained by adjusting a mold for molding the middle resin mold portion 310m. In addition, when a jig (bar material or the like) is used to support the core piece 31m in a predetermined position in the mold when the middle resin mold portion 310m is formed, the core piece 31m is supported by the jig. The portion is not covered with the constituent resin of the resin mold portion 310m and becomes an exposed portion. Therefore, an inner core part provided with the recessed part 312r containing the bottomed hole 3120 and the groove part 3122 is obtained also by adjusting a metal mold | die and this jig | tool. When using a jig, by adjusting the size of the jig, an inner core portion having a relatively small bottomed hole 3120 as shown in this example for each core piece 31m can be obtained.

The arrangement position of the recess 312r, the shape, size, and number of the bottomed hole 3120, the shape, size, and number of the groove 3122 can be selected as appropriate. For example, the bottomed hole 3120 may have a cylindrical shape, a rectangular tube shape, or the like. For the groove portion 3122, refer to the section of the concave portion described in the above embodiment 2-1. When the bottomed hole 3120 is relatively small as in this example, for example, if the groove bottom part and the opening part of the groove part 3122 are made sufficiently large, the inner interposition part 40 of the coil fixing part 4 can be sufficiently provided. In FIG. 6, the size of the bottom of each bottomed hole 3120 is large enough to be provided on one surface (upper surface or lower surface in FIG. 6) of the core piece 31m, and the size of the groove 3122 is substantially equal to that of the inner core portion. Shows an example of the size to reach the full length. The length along the axial direction of the inner circumferential space in the inner interposition part 40 is about 100%, and the length along the circumferential direction is about 40% of the circumferential length of the inner circumferential space. . In addition, since the foamed resin is continuously present from the bottomed hole 3120 to the groove 3122, the corner of the inner wall of the bottomed hole 3120 and the groove bottom of the groove 3122 is covered with the foamed resin. Can prevent cracking.

In the case of having a relatively small bottomed hole 3120 as in this example, it is preferable to use a liquid resin as the non-foamed resin as described above because it can be reliably filled. If the exposed portion of the core piece 31m can be covered with the foamed resin without a gap, the exposed portion can be more reliably protected from the external environment and mechanically protected. Even if the recess 312r is provided in both the upper region and the lower region of the inner core portion as in this example, the liquid resin is substantially removed from the recess 312r by using a liquid resin containing an adhesive component. No spillage and excellent workability. If liquid resin is used, unfoamed resin can be continuously arranged from the bottomed hole 3120 to the groove 3122. If the above-mentioned unfoamed resin sheet is used, even if the groove 3122 is relatively large, the placement work can be performed in a short time, and the workability is excellent.

The foamed resin disposed in the recess 312r functions as an insulating material between the coil 2 and the middle main body in addition to the restriction of the movement of the coil 2 and the protection of the above-described exposed portion, thereby enhancing the insulation. Furthermore, since at least a part of the inner interposition part 40 is provided in the recess 312r, for example, as shown in FIG. 6, the distance between the coil 2 and the middle body part is substantially equal to the thickness of the middle resin mold part 310m. Can be equal. The reactor 1b according to the embodiment 2-2 can be made a small reactor by making the distance between the coil and the core substantially equal to the thickness of the resin mold part 310m. And the insulation between the magnetic core 3b can be ensured.

In the present example and the above-described embodiment 2-1, the case where the concave portions 310r and 312r are provided in the opposing region of the inner core portion has been described. However, the formation position, the number, and the size of the concave portions 310r and 312r are as described above The position can be changed as appropriate according to the arrangement position, number, size, and the like of the fixing portion 4. For example, the concave portion 312r and the coil fixing portion 4 may be provided only in one of the upper region and the lower region of the inner core portion, and the other region may not include both the concave portion 312r and the coil fixing portion 4. it can. In addition, it can be set as a form provided only with a bottomed hole. In this case, if the bottomed hole is provided sufficiently large, the bottomed hole can be used for positioning the unfoamed resin sheet 400 as in the case of the recess 310r of Embodiment 2-1, and the position of the coil fixing portion 4 can be increased. It is determined by accuracy.

[Modification 2]
In the embodiments 1, 2-1, and 2-2, the embodiment in which the magnetic cores 3A, 3B, and 3b include the resin mold portions 310m and 320m has been described. In addition, the resin mold parts 310m and 320m may be omitted, and only the coil fixing part 4 may be provided. In this case, by increasing the thickness of the coil fixing portion 4, insulation between the coil 2 and the middle body portion (particularly, the core piece 31m made of a compacted body), the coil 2 and the side body portion 32 (particularly the inner end surface 32e). Can be secured. In consideration of the expansion coefficient of the unfoamed resin sheet, a relatively thick material or a plurality of thin materials may be laminated so that the inner interposed portion 40 of the coil fixing portion 4 has a desired thickness.

In the second modification, the middle main body (core piece 31m) itself may be provided with a recess in which the constituent resin of the coil fixing portion 4 described in the embodiments 2-1 and 2-2 is disposed (similarly). Embodiment 4 which will be described later as a configuration. If the depth of the recess is as thin as the thickness of the unfoamed resin, reduction of the magnetic path due to the formation of the recess can be suppressed.

[Embodiment 3]
A reactor 1C according to the third embodiment will be described with reference to FIGS.
In the above-described first and second embodiments, the magnetic cores 3A and 3B include the portions (the middle main body portion 31 and the side main body portion 32) constituting the magnetic path, the middle resin mold portion 310m, and the side resin mold portion 320m. The core pieces 31m and 32m provided in the main body portions 31 and 32 have been described as being formed of a green compact. In the reactor 1 </ b> C of the third embodiment, the magnetic core 3 </ b> C does not include the resin mold part, and the part constituting the magnetic path is exposed. Also, the core piece 33m provided in the magnetic core 3C is made of a composite material, and the coil fixing portion 4 is provided in direct contact with the core piece 33m. Hereinafter, it demonstrates in detail focusing on difference with Embodiment 1, 2, and abbreviate | omits detailed description about the overlapping structure and effect.

(Reactor)
Schematic configuration The reactor 1C has a coil 2 (having a pair of winding portions 2a and 2b) formed by spirally winding the winding 2w and a portion (inner core portion 31C) disposed in the coil 2. And a magnetic core 3C that is disposed inside and outside the coil 2 to form a closed magnetic path, and a coil fixing portion 4 that is mainly interposed between the coil 2 and the inner core portion 31C to restrict the movement of the coil 2. The coil fixing part 4 is made of foamed resin, and includes an inner interposition part 40 and a turn interposition part 42 (FIG. 8).

Magnetic core 3C provided in the reactor 1C includes two core pieces 33m and 33m as shown in FIG. Each of the core pieces 33m, 33m has the same shape, and a short columnar portion (hereinafter referred to as an inner core protrusion 31Cs) inserted and disposed in the winding portions 2a, 2b and the coil 2 are substantially disposed. And a columnar outer core portion 32 </ b> C protruding from the coil 2. In other words, the core piece 33m is a solid body in which two inner core protrusions 31Cs and 31Cs protrude from the inner end surface 32e of the outer core part 32C. In this example, the inner core protrusion 31Cs has a rectangular parallelepiped shape with rounded corners, and the outer core portion 32C has a prismatic shape with trapezoidal upper and lower surfaces. The magnetic core 3C forms an annular closed magnetic circuit by assembling the end faces 31e and 31e of the inner core protrusions 31Cs and 31Cs of the core pieces 33m and 33m so as to face each other. In this example, one gap member 31g is interposed between the end faces 31e, 31e of the pair of inner core protrusions 31Cs, 31Cs arranged to face each other. Accordingly, each inner core portion 31C is mainly composed of inner core protrusions 31Cs and 31Cs provided in the core pieces 33m and 33m, and one gap member 31g.

In this example, as shown in FIG. 8, the lower surface of the outer core portion 32C protrudes from the lower surfaces of the inner core protrusions 31Cs and 31Cs, and is substantially the same as the lower surface of the coil 2 (winding portions 2a and 2b). It is one. Therefore, the installation surface of the reactor 1C shown in this example is mainly composed of the lower surfaces (installation surfaces) of the two outer core portions 32C and 32C and the lower surface of the coil 2 (installation surfaces of the winding portions 2a and 2b). The

The core piece 33m is made of a composite material including soft magnetic powder and resin. This composite material is molded using injection molding, cast molding, or the like. When injection molding is used, even a complicated three-dimensional shape can be easily molded. As the soft magnetic powder, the above-mentioned soft magnetic metal powder such as iron or Fe—Si alloy can be preferably used. As the resin used as the binder in the composite material, a thermosetting resin such as an epoxy resin or a thermoplastic resin such as a PPS resin can be used. The content of the soft magnetic powder in the composite material is 20 vol% or more and 80 vol% or less, and further 30 vol% or more and 70 vol% or less when the composite material is 100 vol%. The remainder is mainly a non-metallic organic material such as the above resin. The balance can further include non-metallic inorganic materials such as ceramics such as alumina and silica in addition to the resin (for example, 0.2% by volume to 20% by volume with 100% by volume of the composite material).

The composite material can easily adjust the magnetic properties by adjusting the blending amount of soft magnetic powder, resin, non-metallic inorganic material and the like. By including a nonmagnetic material such as a resin, the composite material can easily be obtained with a low relative magnetic permeability. For this reason, as shown in this example, magnetic saturation can be suppressed even if a relatively thin gap is provided without further providing a gap (gap material 31g and intentional air gap). In high current applications, magnetic saturation is difficult when a gap is provided. In this example, there are a total of two gap members 31g included in the magnetic core 3C, and the total gap length is sufficiently shorter than the magnetic core 3A of the first embodiment. The magnetic core 3A includes two gap members 31g and two resin gaps made of the constituent resin of the middle resin mold portion 310m in one inner core portion, and there are a total of eight gaps.

The core piece 33m composed of the composite material may include a surface resin layer substantially formed by the resin component in the composite material. In this case, insulation between the coil 2 and the inner core portion 31C can be expected by the surface resin layer (which may include the above-described ceramics), and insulating materials such as a resin mold portion and a bobbin can be omitted.

∙ By using the core piece 33m composed of the composite material, the gap can be shortened and the leakage magnetic flux from the gap portion can be reduced. In addition, since the resin component is excellent in insulation, the distance between the coil 2 (winding portions 2a, 2b) and the inner core portion 31C (distance between the coil and the core) can be reduced. For example, the distance between the coil and the core can be 2 mm or less, further 1.5 mm or less, further 1.0 mm or less, and in this example is 1.2 mm or less.

In the reactor 1C, the coil fixing portion 4 is provided in direct contact with the surface of the inner core portion 31C (a part of the core piece 33m) made of the composite material, and the average thickness 4t of the inner interposition portion 40 is equal to the above-described value. It is substantially equal to the coil-core distance. In this example, in the cylindrical inner peripheral space between the inner peripheral surface of the coil 2 (winding portions 2a, 2b) and the outer peripheral surface of the inner core protruding portion 31Cs as shown in FIGS. Coil fixing portions 4 are interposed at the facing position and the left and right facing positions, respectively. Here, when one inner core portion 31C is viewed, a total of eight coil fixing portions 4 to 4 are provided. Further, when one inner core portion 31C is viewed, the coil fixing portion 4 exists only in a part in the circumferential direction of the inner peripheral space and in a part in the axial direction of the inner peripheral space, and the other part becomes a gap. ing. In this example, the total length along the axial direction of the coil fixing portion 4 is about 90% of the axial length of the inner circumferential space, and the total length along the circumferential direction of the coil fixing portion 4 is The inner circumferential space is about 25% of the circumferential length. The arrangement positions of the coil fixing part 4 and the resin sheet 400 shown in FIGS. 7 to 9, the above-described lengths in the coil fixing part 4 and the like are examples.

(Reactor manufacturing method)
Reactor 1C is manufactured as follows, for example. As shown in FIG. 9, unfoamed resin sheets 400 are arranged on the upper and lower opposing surfaces and the left and right opposing surfaces of the rectangular parallelepiped inner core protrusion 31Cs. Here, a state in which the sheet 400 having an adhesive layer or having a certain degree of tackiness is used to be joined to the inner core protrusion 31Cs is shown (this is the same in Embodiments 4 to 13 described later). ). The core pieces 33m and 33m including the sheet 400, the gap material 31g, and the coil 2 are assembled. Thereafter, heat treatment is performed to foam the sheet 400 to form the coil fixing portion 4, whereby the reactor 1C is obtained. The foamed resin is placed in close contact with the inner circumferential space (a part here) between the coil 2 and the inner core portion 31C. When the sheet 400 has an adhesive layer or the foamed resin has an adhesive force, the coil 2 and the inner core portion 31 </ b> C are more firmly bonded by the adhesive layer and the adhesive force. The inner core protrusion 31Cs and the gap material 31g are joined with an adhesive or the like.

(Effects based on main features)
Since the reactor 1C of the third embodiment includes the coil fixing portion 4 made of foamed resin, the inner core portion 31C can be operated during the operation of the reactor 1C even if the sealing material is not provided, as in the first and second embodiments. On the other hand, the movement of the coil 2 in the axial direction, radial direction, and circumferential direction can be restricted. Therefore, the reactor 1 </ b> C can also reduce noise caused by rubbing or collision between the turns of the coil 2 or between the coil 2 and the magnetic core 3 </ b> B, damage to the insulating coating of the coil 2, and the like.

In particular, in the reactor 1C of the third embodiment, the magnetic core 3C is mainly composed of a composite material, the gap can be made thin, and insulating materials such as a resin mold part and a bobbin are omitted, and the coil fixing part 4 is attached to the composite material. Is directly provided, the distance between the coil and the core can be reduced, and further miniaturization can be achieved. Further, in the reactor 1C, the coil fixing part 4 has both the function of suppressing the movement of the coil 2 and the insulating function between the coil 2 and the inner core part 31C, so that the number of parts is small and the assembly workability is excellent.

[Embodiment 4]
A reactor 1D of the fourth embodiment will be described with reference to FIGS.
In the above-described third embodiment, the mode in which the coil fixing portion 4 is in direct contact with the core piece 33m made of a composite material has been described. In the reactor 1D of the fourth embodiment, a concave portion 31r is provided in the middle main body portion of the inner core portion, that is, the inner core protruding portion 31Cs of the core piece 33m, and a part of the foamed resin constituting the coil fixing portion 4 in the concave portion 31r. One of the differences from the third embodiment is that is arranged. Further, the point that the middle main body portion is provided with the recess 31r is one of the differences from the embodiment 2-1, in which the middle resin mold portion 310m is provided with the recess 310r. Hereinafter, detailed description will be made centering on differences from Embodiments 2-1 and 3, and detailed description of overlapping configurations and effects will be omitted.

(Reactor)
-Magnetic core The magnetic core provided in the reactor 1D has the same basic configuration as that of the magnetic core 3C of the third embodiment. Further, as shown in FIG. 12, the inner core protrusions 31Cs and 31Cs in which the coil fixing part 4 is arranged are arranged. The upper and lower opposing surfaces and the left and right opposing surfaces are respectively provided with recesses 31r. That is, the recess 31r is directly provided in the core pieces 33m and 33m. For details of the recess 31r, refer to the section of the recess described in the embodiment 2-1.

As shown in FIGS. 10 and 11, the recess 31r is provided extremely shallow in the vicinity of the outer peripheral surface of the inner core protrusions 31Cs and 31Cs. The depth of the recess 31r is typically about the thickness of the unfoamed resin sheet 400 (FIG. 12). Therefore, although the inner core protrusions 31Cs and 31Cs are portions through which the magnetic flux passes, a decrease in the magnetic path area due to the provision of the recess 31r can be suppressed. Considering the suppression of the decrease in the magnetic path area, it is considered that the depth of the recess 31r is preferably about 100% to 130%, more preferably about 120% or less of the thickness of the sheet 400. The sectional shape and planar shape of the recess 31r in this example are rectangular shapes corresponding to the sheet 400 having a rectangular sectional shape and planar shape.

(Reactor manufacturing method)
The reactor 1D can be manufactured in the same manner as in the third embodiment. Briefly, as shown in FIG. 12, core pieces 33m and 33m having a recess 31r are prepared. Even when the concave portion 31r is provided, the core piece 33m can be easily formed by injection molding or the like (this also applies to the core piece 34m described later). The unfoamed resin sheet 400 is disposed in each of the recesses 31r, and the core pieces 33m and 33m, the gap material 31g, and the coil 2 are assembled. Thereafter, heat treatment is performed to foam the sheet 400 to form the coil fixing portion 4, whereby the reactor 1D is obtained. A part of the foamed resin is disposed in the recess 31r, and another part leaks out of the recess 31r, and the inner peripheral surface of the coil 2 (winding portions 2a and 2b) and the outer peripheral surface of the inner core protrusion 31Cs. Arranged between the portion excluding the recess 31r and forming the inner interposition portion 40, another part forms the turn interposition portion 42 (FIG. 11). The foamed resin is in close contact with the inner core protrusion 31Cs and the turn. The size of the coil fixing portion 4 in this example is substantially the same as that of the third embodiment.

(Effects based on main features)
Since the reactor 1D according to the fourth embodiment includes the coil fixing portion 4 made of a foamed resin, the inner core portion can be provided during the operation of the reactor 1D even when the reactor 1D does not include a sealing material as in the first to third embodiments. In contrast, the movement of the coil 2 in the axial direction, radial direction, and circumferential direction can be restricted. Accordingly, the reactor 1D can also reduce noise caused by rubbing or collision between the turns of the coil 2 or between the coil 2 and the magnetic core 3C, damage to the insulation coating of the coil 2, and the like.

In particular, the reactor 1D of the fourth embodiment is provided with the recess 31r in the inner core portion 31C as in the case of the embodiment 2-1, so that the positioning and arrangement of the resin sheet 400 can be easily performed in the manufacturing process and excellent in assembling workability. Excellent manufacturability. Further, the reactor 1D can reduce the distance between the coil and the core due to the magnetic core 3C being made of a composite material as in the third embodiment, and can also reduce the middle main body portion (core piece 33m) of the inner core portion 31C. Since the inner core protrusion 31Cs) is directly provided with the recess 31r, the amount of resin protrusion from the recess 31r can be reduced even if the size of the coil fixing portion 4 is the same as that of the third embodiment. As described in the embodiment 2-2, the distance between the coil and the core can be further shortened. Accordingly, the reactor 1D can be further downsized. Since the distance between the coil and the core can be reduced, the amount of magnetic flux (cross-sectional area) that can pass through the inner core portion 31C can be increased. As a result, the reactor 1D does not substantially cause a decrease in magnetic characteristics due to a decrease in the magnetic path area caused by the recess 31r.

[Embodiment 5]
A reactor 1E of the fifth embodiment will be described with reference to FIGS.
In the above-described fourth embodiment, the embodiment has been described in which the core piece 33m itself made of a composite material is provided with the concave portion 31r in which a part of the foamed resin constituting the coil fixing portion 4 is disposed. In the reactor 1E of the fifth embodiment, as in the fourth embodiment, the middle main body portion of the inner core portion, that is, the inner core protrusion 31Cs of the core piece 33m is provided with the concave portion 31r, and the formation position of the concave portion 31r is the fourth embodiment. Is different. In the reactor 1E, the recesses 31r are respectively provided at the four corners of the rectangular parallelepiped inner core protrusion 31Cs with rounded corners as shown in FIGS. Hereinafter, it demonstrates in detail centering around difference with Embodiment 4, and abbreviate | omits detailed description about the overlapping structure and effect.

(Reactor)
-Concave portion The magnetic core provided in the reactor 1E has the same basic configuration as the magnetic core 3C of the third and fourth embodiments, and further, the inner core protrusions 31Cs, 31Cs in which the coil fixing portion 4 is disposed as shown in FIG. In each of the four corners, recesses 31r are provided. Similarly to the fourth embodiment, the reactor 1E also includes the concave portion 31r and the coil fixing portion 4 at the facing position (FIG. 14). Although the inner core protrusions 31Cs and 31Cs form a magnetic path as described above, the corner portion where the recess 31r is provided is at a position where there is less magnetic flux passage in the vicinity of the outer peripheral surface where the passage of the magnetic flux is smaller than the inside. is there. By providing the concave portion 31r in such a specific portion, the reduction of the magnetic path area due to the provision of the concave portion 31r can be further suppressed, or the magnetic path is not substantially reduced. For details of the other recesses 31r, refer to the description of the recesses in Embodiment 2-1, and the description of the recesses in Embodiment 3.

Furthermore, if the inner core protrusions 31Cs and 31Cs are provided with recesses 31r at the corners, the recess 31r has a curved cross section (see FIGS. 13 and 15), and therefore the recess 31r has a rectangular cross section. Compared to the form 4, the moldability (demoldability) of the core piece 33m is excellent. Therefore, it can contribute to the improvement of the manufacturability of the core piece 33m, and consequently the manufacturability of the reactor 1E.

(Reactor manufacturing method)
The reactor 1E can be manufactured basically in the same manner as in the fourth embodiment. In particular, in the reactor 1E, it is preferable that the unfoamed resin sheet 400 is excellent in flexibility in addition to having an adhesive layer or having a certain degree of tackiness. This is because the sheet 400 can be easily deformed along the concave portion 31r having a curved cross section as shown in FIG. As a result, it is expected that the sheet 400 is more difficult to drop from the recess 31r. A part of the foamed resin is disposed in the recess 31r, and another part leaks out of the recess 31r and is a recess in the inner peripheral surface of the coil 2 (winding portions 2a, 2b) and the outer peripheral surface of the inner core protrusion 31Cs. The inner interposition part 40 is formed by being arranged between the parts excluding 31r, and another part forms the turn interposition part 42 (FIG. 14). The foamed resin is in close contact with the inner core protrusion 31Cs and the turn. The total length along the axial direction of the coil fixing portion 4 in this example is substantially the same as that of the fourth embodiment, and the total length along the circumferential direction of the coil fixing portion 4 is the circumferential length of the inner circumferential space. About 20% of the length.

(Effects based on main features)
Since the reactor 1E of the fifth embodiment includes the coil fixing portion 4 made of foamed resin as in the fourth embodiment, and further includes the concave portion 31r directly in the middle main body portion of the inner core portion 31C. 1. The coil 2 can be fixed without a sealing material. 2. Excellent assembly workability and excellent manufacturability. Further downsizing can be achieved.

In particular, although the reactor 1E of the fifth embodiment includes the recess 31r in the middle main body itself, in addition to being able to reduce the distance between the coil and the core as described above, of the inner core portion 31C of the magnetic core 3C, the magnetic flux Since the concave portion 31r is provided at a position where it is relatively difficult to pass, reduction of the magnetic path area caused by the concave portion 31r can be suppressed, and the magnetic characteristics are excellent. Moreover, it is excellent in the moldability of the core piece 33m as mentioned above.

[Embodiment 6]
A reactor 1F according to the sixth embodiment will be described with reference to FIGS.
In Embodiments 3 to 5 described above, the core piece 33m included in the magnetic core 3C is made of a composite material, and the coil 2 includes two winding portions 2a and 2b. In the reactor 1F of the sixth embodiment, the coil 2F includes only one winding part 2c. Hereinafter, detailed description will be made centering on differences from the third to fifth embodiments, and detailed description of overlapping configurations and effects will be omitted.

Schematic configuration The reactor 1F has a coil 2F (winding portion 2c) formed by winding the winding 2w in a spiral shape and a portion (inner core portion 31F, FIGS. 17 and 18) disposed in the coil 2F. A magnetic core 3F that is disposed inside and outside the coil 2F to form a closed magnetic path, and a coil fixing portion 4 that is mainly interposed between the inner core portion 31F and the coil 2F and restricts the movement of the coil 2F (FIG. 16, FIG. FIG. 17). The coil fixing part 4 is made of a foamed resin and includes an inner interposition part 40 and a turn interposition part 42 (FIG. 17).

-Coil The coil 2F includes a cylindrical winding portion 2c formed by spirally winding one continuous winding 2w as shown in FIG. 18, and the end 2e of the winding 2w is appropriately It is pulled out in any direction. In this example, the winding part 2c is an edgewise coil using the covered rectangular wire described in the first embodiment, and has a shape obtained by rounding the inner and outer corners of the square tube.

Magnetic core 3F provided in the magnetic core reactor 1F includes two core pieces 34m and 34m as shown in FIG. 18, and a part between the core pieces 34m and 34m (between inner core protrusions 31Fs and 31Fs described later). With a thin air gap. Each of the core pieces 34m and 34m has the same shape, which is similar to a so-called EE type core. More specifically, the core piece 34m includes a short columnar portion (inner core protrusion 31Fs) inserted and arranged in the winding portion 2c, and an outer core portion 32F where the coil 2F is not substantially arranged. The outer core portion 32F is connected to the inner core protrusion portion 31Fs, and is opposed to the end face of the coil 2F (hereinafter referred to as a connection portion 32Fr), and a part of the outer peripheral surface of the coil 2F is continuous to the connection portion 32Fr. And a portion (hereinafter referred to as the outer peripheral portion 32Fo) arranged to cover. In the core piece 34m, the so-called inner core protrusion 31Fs protrudes from the central portion of the inner end surface 32e of the connecting portion 32Fr, and the outer peripheral portions 32Fo and 32Fo respectively extend from the portions near both edges of the inner end surface 32e to the inner core protrusion 31Fs. It is a solid projecting in parallel. In this example, the inner core protrusion 31Fs has a rectangular parallelepiped shape with rounded corners, and the connecting portion 32Fr and the outer peripheral portion 32Fo have a flat plate shape.

The magnetic core 3F forms an annular closed magnetic circuit by assembling the end faces 31e, 31e of the inner core protrusions 31Fs, 31Fs of both core pieces 34m, 34m and the end faces of the outer peripheral part 32Fo so as to face each other. This closed magnetic path consists of two inner core protrusions 31Fs, 31Fs → the connecting portion 32Fr of one core piece 34m → the outer peripheral portion 32Fo of one core piece 34m → the outer peripheral portion 32Fo of the other core piece 34m → the other core piece. A loop of 34m connecting portion 32Fr is formed. Both core pieces 34m, 34m are assembled, and the inner core portion 31F is substantially formed by inner core protrusions 31Fs, 31Fs of both core pieces 34m, 34m and an air gap provided between the inner core protrusions 31Fs, 31Fs. Configured. The winding part 2c is arranged in a gap between the inner core protrusion 31Fs formed by assembling both core pieces 34m and 34m and the outer peripheral parts 32Fo and 32Fo, and the end face of the winding part 2c is the inner side of the connecting part 32Fo. It contacts or faces the end face 32e.

In this example, as shown in FIG. 17, the lower surfaces of the connecting portion 32Fr and the outer peripheral portion 32Fo protrude from the lower surface of the inner core protruding portion 31Fs and are substantially flush with the lower surface of the coil 2F (winding portion 2c). It is. Therefore, the installation surface of the reactor 1F shown in this example is mainly composed of the lower surfaces (installation surfaces) of the two outer core portions 32F and 32F and the lower surface (installation surface of the winding portion 2c) of the coil 2F.

The core piece 34m is also composed of a composite material including soft magnetic powder and resin. In particular, the magnetic core 3F of the sixth embodiment has one gap, which is thinner than the gap of the magnetic core 3C of the third to fifth embodiments. Furthermore, the reactor 1F also does not include an insulating material such as the above-described bobbin, but includes the coil fixing portion 4 so as to directly contact the surface of the inner core portion 31F. Therefore, the distance between the coil and the core is small. The average thickness 4t of the inner interposition part 40 is substantially equal to and thinner than the distance between the coil and the core (in this example, 1.2 mm or less).

In addition, in this example, as shown in FIG. 17, in the cylindrical inner peripheral space between the inner peripheral surface of the coil 2F (winding portion 2c) and the outer peripheral surface of the inner core portion 31F, upper and lower opposing positions, and Coil fixing portions 4 are interposed at the left and right facing positions, respectively. Moreover, in this example, the coil fixing | fixed part 4 exists only in a part of the circumferential direction of the said inner peripheral space, and a part of the axial direction of the said inner peripheral space, and the other part is a clearance gap. The total length along the axial direction of the coil fixing portion 4 is about 77% of the axial length of the inner circumferential space, and the total length along the circumferential direction of the coil fixing portion 4 is equal to the inner circumference. It is about 40% of the circumferential length of the space. The coil fixing part 4, the arrangement position of the resin sheet 400, the above-described length in the coil fixing part 4 and the like shown in FIGS. 16 to 18 are examples. In the magnetic core 3F shown in this example and the following seventh, eighth, twelfth, and thirteenth embodiments, the entire circumference of the annular end surface of the winding portion 2c and the inner end surface 32e of the coupling portion 32Fr are disposed to face each other. It is easy to provide the above-described end fixing portion 44 (FIG. 1) and the like. Instead of the end fixing portion 44, a frame-like member made of an insulating material or the like can be arranged. By disposing the frame-shaped member, it is easy to improve the insulation between the end face of the winding portion 2c and the inner end face 32e, or to fix the coil 2F. The points related to the frame-like member are the same in the seventh, eighth, twelfth and thirteenth embodiments described later.

(Reactor manufacturing method)
The reactor 1F can be manufactured in the same manner as in the third embodiment. Briefly, as shown in FIG. 18, an unfoamed resin sheet 400 having adhesiveness or the like is preferably disposed at an appropriate position of the inner core protrusion 31Fs, and the coil 2F and the magnetic core 3F are assembled. After that, heat treatment is performed to foam the sheet 400 to form the coil fixing portion 4.

(Effects based on main features)
Since the reactor 1F of the sixth embodiment includes the coil fixing portion 4 made of foamed resin, the inner core portion 31F can be operated during the operation of the reactor 1F even if the sealing material is not provided as in the first to fifth embodiments. On the other hand, the movement of the coil 2F in the axial direction, radial direction, and circumferential direction can be restricted. Accordingly, the reactor 1F can also reduce noise caused by friction or collision between the turns of the coil 2F or between the coil 2F and the magnetic core 3F, damage to the insulation coating of the coil 2F, and the like.

In particular, in the reactor 1F of the sixth embodiment, (i) the magnetic core 3F is mainly composed of a composite material, the gap can be further reduced, and the insulating material is omitted, and the coil fixing portion 4 is directly attached to the composite material. Since it is provided, the distance between the coil and the core can be reduced, and (ii) the number of the winding portions 2c is one, so that further downsizing can be achieved. Furthermore, since the reactor 1F has a thin gap, the copper loss caused by the leakage magnetic flux from the gap portion can be further reduced and the loss is low. Further, the reactor 1F also has a small number of parts because the coil fixing portion 4 has both a function of suppressing the movement of the coil 2F and an insulating function between the coil 2F and the inner core portion 31F. In addition, it can replace with an air gap and can provide the gap material 31g like Embodiment 12 and 13 mentioned later. This also applies to Embodiments 7 and 8 described later.

[Embodiment 7]
A reactor 1G of the seventh embodiment will be described with reference to FIGS.
In Embodiment 6 described above, the outer peripheral surface of the inner core portion 31F (inner core protrusion portion 31Fs) has a uniform and smooth surface, and the coil fixing portion 4 is in direct contact with the outer peripheral surface. A reactor 1G according to the seventh embodiment is provided with a concave portion 31Fr in the middle main body portion of the inner core portion 31F, that is, the inner core protrusion portion 31Fs of the core piece 34m, and is one of the foamed resins constituting the coil fixing portion 4 in the concave portion 31Fr. One of the differences from the sixth embodiment is that the portion is arranged. Moreover, the point which equips the middle main-body part with the recessed part 31Fr is similar to the reactor 1D of Embodiment 4. FIG. Hereinafter, the difference from the sixth embodiment or the similarities with the fourth embodiment will be mainly described, and the detailed description of the configurations and effects overlapping with the sixth embodiment will be omitted.

(Reactor)
Magnetic core The magnetic core provided in the reactor 1G has the same basic configuration as that of the magnetic core 3F of the sixth embodiment. Further, as shown in FIG. 21, the inner core protrusions 31Fs and 31Fs in which the coil fixing portion 4 is disposed. The upper and lower opposing surfaces and the left and right opposing surfaces are each provided with a recess 31Fr. That is, the recesses 31Fr are directly provided in the core pieces 34m, 34m. For details of the recess 31Fr, refer to the section of the recess described in the embodiment 2-1.

As shown in FIGS. 19 and 21, the recess 31 </ b> Fr is provided extremely shallow in the vicinity of the outer peripheral surface of the inner core protrusions 31 </ b> Fs and 31 </ b> Fs as in the fourth embodiment, and the depth thereof is typically unfoamed. The thickness of the resin sheet 400 (FIG. 21). The cross-sectional shape and planar shape of the recess 31Fr in this example are rectangular shapes corresponding to the sheet 400 having a rectangular cross-sectional shape and planar shape.

(Reactor manufacturing method)
The reactor 1G can be manufactured in the same manner as in the sixth embodiment. Briefly, as shown in FIG. 21, core pieces 34m and 34m having a recess 31Fr are prepared, and an unfoamed resin sheet 400, preferably having adhesiveness, is disposed in the recess 31Fr. 34m, 34m and the coil 2F are assembled. Then, the reactor 1G is obtained by performing heat processing to foam the sheet 400 and forming the coil fixing portion 4. Part of the foamed resin is disposed in the recess 31Fr, and another part leaks from the recess 31Fr and is disposed in the inner peripheral space (here, part) between the coil 2F and the inner core part 31F. The part 40 is formed, and another part forms the turn interposition part 42 (FIG. 20). The foamed resin is in close contact with the inner core protrusion 31Fs and the turn. The size of the coil fixing portion 4 in this example is substantially the same as that of the sixth embodiment.

(Effects based on main features)
Since the reactor 1G of the seventh embodiment includes the coil fixing portion 4 made of foamed resin, the inner core portion 31F can be operated during the operation of the reactor 1G even if the sealing material is not provided, as in the first to sixth embodiments. On the other hand, the movement of the coil 2F in the axial direction, radial direction, and circumferential direction can be restricted. Accordingly, the reactor 1G can also reduce noise caused by rubbing and collision between the turns of the coil 2F, between the coil 2F and the magnetic core 3F, damage to the insulation coating of the coil 2F, and the like.

In particular, in the reactor 1G of the seventh embodiment, the magnetic core 3F is mainly composed of a composite material as in the fourth embodiment, and the concave portion is formed in the middle main body portion (the inner core protrusion portion 31Fs of the core piece 34m) of the inner core portion 31F. 31r is provided directly. Therefore, the reactor 1G is excellent in assembling workability as in the fourth embodiment, can further shorten the distance between the coil and the core, can be further reduced in size, and can suppress reduction in magnetic characteristics caused by the recess 31r. Can do.

[Embodiment 8]
A reactor 1H according to the eighth embodiment will be described with reference to FIGS.
In the above-described seventh embodiment, the embodiment has been described in which the core piece 34m itself made of a composite material is provided with the concave portion 31Fr in which a part of the foamed resin constituting the coil fixing portion 4 is disposed. In the reactor 1H of the eighth embodiment, as in the seventh embodiment, the middle main body portion of the inner core portion 31F, that is, the inner core protrusion portion 31Fs of the core piece 34m is provided with the concave portion 31Fr, and the formation position of the concave portion 31Fr is the embodiment. Different from 7. In the reactor 1H, the recesses 31Fr are respectively provided at the four corners of the rectangular parallelepiped inner core protrusion 31Fs with rounded corners as shown in FIGS. The point which equips the corner | angular part of the inner core protrusion part 31Fs with the recessed part 31Fr is similar to the reactor 1E of Embodiment 5. FIG. Hereinafter, the differences from the seventh embodiment or the similarities with the fifth embodiment will be mainly described, and detailed description of the configurations and effects overlapping with the seventh embodiment will be omitted.

-Concave part The magnetic core 3F with which the reactor 1H is equipped has the same basic structure as the magnetic core 3F of Embodiments 6 and 7. Furthermore, as shown in FIG. 24, concave portions 31Fr are provided at four corners of the inner core protrusions 31Fs and 31Fs where the coil fixing portion 4 is disposed. Reactor 1H includes concave portion 31Fr and coil fixing portion 4 at the opposite positions as in the seventh embodiment (FIG. 23). Moreover, the reactor 1H includes a concave section 31Fr having a curved cross section at a location where the magnetic flux is relatively difficult to pass in the inner core portion 31F as in the fifth embodiment (FIG. 24).

(Reactor manufacturing method)
The reactor 1H can be manufactured basically in the same manner as in the seventh embodiment. In particular, in the reactor 1H, the non-foamed resin sheet 400 as in the fifth embodiment has adhesiveness and is excellent in flexibility, and is easy to be arranged at the time of assembly and is not easily dropped from the recess 31Fr. preferable. A part of the foamed resin is disposed in the recess 31r, and another part leaks from the recess 31Fr and excludes the recess 31Fr from the inner peripheral surface of the winding portion 2c of the coil 2F and the outer peripheral surface of the inner core protrusion 31Fs. The inner interposition part 40 is formed between the two parts, and another part forms the turn interposition part 42 (FIG. 23). The foamed resin is in close contact with the inner core protrusion 31Fs and the turn. The total length along the axial direction of the coil fixing portion 4 in this example is substantially the same as that of the seventh embodiment, and the total length along the circumferential direction of the coil fixing portion 4 is the circumferential length of the inner peripheral space. About 25% of the length.

(Effects based on main features)
Since the reactor 1H of the eighth embodiment includes the coil fixing portion 4 made of foamed resin as in the seventh embodiment, and directly includes the recess 31Fr in the middle main body portion of the inner core portion 31F. 1. The coil 2F can be fixed even without a sealing material. 2. Excellent assembly workability and excellent manufacturability. Further downsizing can be achieved. In addition, although the reactor 1H of the eighth embodiment includes the recess 31Fr in the middle main body itself, as in the fifth embodiment, in addition to being able to reduce the distance between the coil and the core as described above, the magnetic core 3F has a magnetic core 3F. Since the concave portion 31r is provided at a place where it is difficult to affect the path, the reduction of the magnetic path due to the concave portion 31r can be suppressed, and the magnetic characteristics are excellent. Moreover, it is excellent in the moldability of the core piece 34m.

[Embodiments 9 to 13]
In the first to eighth embodiments, a flat portion is formed with respect to the rectangular cylindrical inner circumferential space provided between one winding portion provided in the coil and one inner core portion disposed in the winding portion. The embodiment in which the rectangular inner interposition part 40 exists in the above or the form in which the curved inner interposition part 40 exists in the corner has been described. In the ninth to thirteenth embodiments, there is a form in which the inner intervening portion 40 is continuous over a plurality of flat portions with respect to the rectangular cylindrical inner space, and the inner intervening portion 40 is shaped in the first to the third embodiments. This is one of the differences from 8. The ninth to thirteenth embodiments are more excellent in manufacturability because the inner interposition part 40 has a specific shape. Hereinafter, the difference and the effect thereof will be described in detail, and detailed description of the overlapping configuration and effect will be omitted.

[Embodiment 9]
A reactor 1I according to the ninth embodiment will be described with reference to FIGS.
The basic configuration of the reactor 1I of the ninth embodiment is the same as that of the reactor 1B of the embodiment 2-1, the coil 2 having a pair of winding portions 2a and 2b, the magnetic core 3B including the inner core portion, and the foam The coil fixing part 4 which has resin and contains the inner interposition part 40 and the turn interposition part 42 is provided. The magnetic core 3B includes core pieces 31m and 32m (FIG. 26) made of a compacted body and the like, and resin mold portions 310m and 320m, and includes an L-shape including an inner core portion mainly composed of the core piece 31m. The inner core component 310B (FIG. 26). Similarly to the embodiment 2-1, the inner core component 310B is provided with a recess 310r in the core covering portion mainly covering the core piece 31m, and a part of the inner interposed portion 40 is disposed in the recess 310r (FIG. 25).

Reactor 1I has a rectangular cylindrical inner shape formed between the inner peripheral surface of one winding portion 2a (2b) and the outer peripheral surface of the inner core portion disposed in this winding portion 2a (2b). One circumferential interposition part 40 is provided in the circumferential space in the circumferential direction. The inner interposition part 40 of this example is П-shaped (gate-shaped) along the outer periphery of a rectangular parallelepiped inner core part with rounded corners. Specifically, the inner interposition part 40 extends over three flat parts (the upper part and the left and right parts in FIG. 25) of the rectangular cylindrical inner peripheral space and the two corners connecting them. Is provided. The inner interposition part 40 does not exist in the lower flat part on the installation side in the inner peripheral space, and is a gap. In Embodiment 9, the length along the axial direction of the inner circumferential space in the inner interposition part 40 is about 80%, and the length along the circumferential direction is about 70 of the circumferential length of the inner circumferential space. %.

The core covering portion of the inner core component 310B is provided with a П-shaped concave portion 310r across the upper surface, the left and right surfaces, and the two upper corners connecting them. As shown in FIG. 26, the central portion of one unfoamed resin sheet 400П along the concave portion 310r is disposed on the upper surface of the concave portion 310r, and both side portions thereof are respectively disposed on the left side and the right side of the concave portion 310r. After placement, the coil fixing part 4 including the П-shaped inner interposition part 40 can be formed by foaming. The unfoamed resin sheet 400П preferably has excellent flexibility so that it can be easily bent along the recess 310r, in addition to having adhesiveness.

Reactor 1I is excellent in manufacturability from the following points.
-In the manufacturing process, the number of unfoamed resin sheets used for one inner core portion is small compared to Embodiment 2-1, and the number of placement steps can be reduced.- Although the unfoamed resin sheet is relatively large, There is enough space around the inner core of the rectangular parallelepiped when placing the resin sheet, and it can be easily placed

Further, in the reactor 1I, although the number of unfoamed resin sheets is small, the coil fixing portion 4 is present including the plurality of flat portions of the inner circumferential space and including the left and right facing positions. Can be firmly fixed. Furthermore, the reactor 1I can use the clearance on the installation side of the inner peripheral space as a contact area with the liquid refrigerant or a storage area of the heat dissipation sheet, and can improve heat dissipation (this point will be described later in Embodiments 10 to 13). Is the same).

The ninth embodiment can be modified as follows.
The three flat portions of the rectangular cylindrical inner space where the inner intervening portion 40 is present are the lower portion and the left and right portions, or the upper and lower portions and the right and left portions. (Refer to Embodiment 11 described later). Or the inner interposition part 40 shall be provided over one corner | angular part and two flat parts which pinch | interpose this corner | angular part (refer Embodiment 10 mentioned later). Even in these modified forms, the number of unfoamed resin sheets used is small as described above, and since there is a sufficient space for arranging the unfoamed resin sheets around each inner core portion, the productivity is excellent. The coil 2 can be firmly fixed.

[Embodiments 10 and 11]
With reference to FIG. 27, FIG. 28, the reactor 1J of Embodiment 10 is demonstrated, and the reactor of Embodiment 11 is demonstrated with reference to FIG.

The basic configuration of the reactor of the tenth and eleventh embodiments is the same as that of the reactor 1D of the fourth embodiment, the coil 2 having a pair of winding portions 2a and 2b, the magnetic core 3C including the inner core portion 31C, and foaming. The coil fixing part 4 (FIG. 27) which has resin and includes the inner interposition part 40 and the turn interposition part 42 is provided. The magnetic core 3C includes a pair of core pieces 33m and 33m made of a composite material and gap members 31g and 31g (FIGS. 28 and 29). Each of the core pieces 33m and 33m includes a pair of inner core protrusions 31Cs and 31Cs that constitute the inner core portion 31C. Each inner core protrusion 31Cs includes a recess 31r as in the fourth embodiment, and a part of the inner interposition part 40 is disposed in the recess 31r.

The reactors of the tenth and eleventh embodiments are formed between the inner peripheral surface of one winding portion 2a (2b) and the outer peripheral surface of the inner core protrusion 31Cs disposed in the winding portion 2a (2b). One inner interposed portion 40 that is continuous in the circumferential direction is provided in the rectangular cylindrical inner circumferential space.

The inner interposition part 40 of the reactor 1J according to the tenth embodiment has a Γ shape (saddle shape) or a bowl shape along the outer periphery of a rectangular parallelepiped inner core protrusion 31Cs with rounded corners. Specifically, as shown in FIG. 27, the inner interposer 40 includes one corner (in this case, the upper corner) of the rectangular cylindrical inner space and two flat portions sandwiching the corner. (Here, the upper flat portion and the left or right flat outer portion). In the tenth embodiment, the length along the axial direction of the inner circumferential space in the inner interposed portion 40 is about 85%, and the length along the circumferential direction is about 40 of the circumferential length of the inner circumferential space. %.

The inner intervening portion of the reactor of the eleventh embodiment has a [shape or] shape along the outer periphery of a rectangular parallelepiped inner core protrusion 31Cs with rounded corners. Specifically, the inner intervening portion is provided across three flat portions (here, the upper and lower flat portions and the right or left side outer flat portion) and the two corners connecting them. . In the eleventh embodiment, the length along the axial direction of the inner circumferential space in the inner interposition is about 85%, and the length along the circumferential direction is about 60% of the circumferential length of the inner circumferential space. It is.

In the reactors of the tenth and eleventh embodiments, the inner interposition part 40 is provided except for the adjacent regions in the pair of inner core protrusions 31Cs and 31Cs provided in one core piece 33m. That is, the inner interposition part 40 does not exist in the adjacent inner flat part in the rectangular cylindrical inner peripheral space, and is a gap.

The inner core protrusions 31Cs and 31Cs of the reactor 1J according to the tenth embodiment have a Γ-shaped or bowl-shaped recess extending over the upper surface, the upper corner portion continuing from the upper surface, and the outer surface continuing from the corner portion. 31r (FIG. 28) is provided. The inner core protrusions 31Cs and 31Cs of the reactor according to the eleventh embodiment have an upper surface, an upper corner that follows the upper surface, an outer surface that continues to the corner, a lower corner that continues to the outer surface, and the corner. A [shaped or] -shaped recess 31r (FIG. 29) is provided over the lower surface following the.

As shown in FIGS. 28 and 29, along the concave portion 31r, one unfoamed resin sheet 400Γ, 400￢ (FIG. 28) and resin sheet 400 [400] (FIG. 29) are removed from the upper surface of the concave portion 31r. The coil fixing part 4 including the Γ-shaped inner interposition part 40 or the coil fixing part including the [shaped inner interposition part or the like] can be formed by foaming after being arranged around the lower surface appropriately through the side surface. The unfoamed resin sheets 400 Γ, 400 ４００, 400 [, 400] preferably have excellent flexibility so that they can be easily bent along the recess 31 r in addition to having adhesiveness.

The reactors of the tenth and eleventh embodiments are excellent in manufacturability from the following points.
In the manufacturing process, the number of unfoamed resin sheets used for one inner core portion 31C is less than that of the fourth embodiment, and the number of arrangement steps can be reduced. Although the unfoamed resin sheet is relatively large, a rectangular parallelepiped The resin sheet can be arranged from the upper side of the inner core protrusion 31Cs or from the outside, and a part of the resin sheet is arranged in an adjacent region in the pair of inner core portions 31C (inner core convex portions 31Cs). Compared to the case, there is enough space for placement and easy placement

In addition, in the reactors of the tenth and eleventh embodiments, although the number of unfoamed resin sheets is small, there is a coil fixing portion that includes a plurality of flat portions in the inner circumferential space, and the coil 2 is strengthened. Can be fixed. In the reactor according to the eleventh embodiment, the coil 2 can be firmly fixed because the coil fixing portion is present including the upper and lower opposing positions.

In addition, in the tenth embodiment, the two flat portions of the rectangular cylindrical inner peripheral space where the inner intervening portion exists are used as the upper portion and the inner portion, or the lower portion and the outer portion or the inner portion. Or part. In the eleventh embodiment, the three flat portions of the rectangular cylindrical inner peripheral space where the inner intervening portion exists are used as the upper portion and the left and right portions as in the ninth embodiment, or the lower portion and the left and right portions. Or a side part. Even in these cases, the number of unfoamed resin sheets used is small as described above, and the coil 2 can be firmly fixed.

[Embodiments 12 and 13]
The reactor of the twelfth embodiment will be described with reference to FIGS. 30 and 31, and the reactor of the thirteenth embodiment will be described with reference to FIG.

The basic configuration of the reactors of the twelfth and thirteenth embodiments is the same as that of the reactor 1G of the seventh embodiment. The coil 2F having one winding portion 2c, the magnetic core 3F including the inner core portion 31F, and the foamed resin are used. And a coil fixing portion 4 (FIG. 30, reactor 1L) including the inner interposed portion 40 and the turn interposed portion 42. The magnetic core 3F includes a pair of core pieces 34m and 34m made of a composite material and a gap material 31g. Each of the core pieces 34m and 34m forms a pair of inner core protrusions constituting the inner core portion 31F. 31Fs and 31Fs are included. A gap material 31g is interposed between the inner core protrusions 31Fs and 31Fs. Each inner core protrusion 31Fs includes a recess 31Fr as in the seventh embodiment, and a part of the inner interposition part is disposed in the recess 31Fr.

Reactor 1L of the twelfth embodiment is a rectangular cylindrical inner peripheral space formed between the inner peripheral surface of winding part 2c and the outer peripheral surface of inner core protrusion 31Fs arranged in winding part 2c. The inner interposition part 40 which continues in the circumferential direction is provided. The reactor of the thirteenth embodiment includes two inner interposed portions 40 that are continuous in the circumferential direction in the rectangular cylindrical inner circumferential space.

The inner interposition part 40 of the reactor 1L of the twelfth embodiment is П-shaped (gate-shaped) along the outer periphery of the rectangular parallelepiped inner core protrusion 31Fs with rounded corners, as in the ninth embodiment. It is provided across the flat portion, the left and right flat portions, and the two corners connecting them. The inner interposition part 40 does not exist in the lower flat part on the installation side in the inner peripheral space, and is a gap. In the twelfth embodiment, the length of the inner space 40 along the axial direction of the inner circumferential space is about 90%, and the length along the circumferential direction is about 60 of the circumferential length of the inner circumferential space. %.

Each inner interposition part of the reactor according to the thirteenth embodiment is arranged in a П shape (gate shape) or U shape provided so as to face the upper and lower sides along the outer periphery of a rectangular parallelepiped inner core protrusion 31Fs with rounded corners. Is. The upper П-shaped inner intervening portion is similar to that of the twelfth embodiment, and the lower U-shaped inner intervening portion is obtained by inverting the upper and lower П-shaped inner intervening portions. The upper П-shaped inner intervening portion is provided across the upper flat portion, the left and right flat portions, and the two upper corners connecting them. The lower U-shaped inner intervening portion is provided across the lower flat portion, the other portions of the left and right flat portions, and the two lower corners connecting them. In the thirteenth embodiment, the length along the axial direction of the inner circumferential space at the inner interposition is about 90%, and the total length along the circumferential direction is about 95 of the circumferential length of the inner circumferential space. %.

And each inner core protrusion 31Fs, 31Fs of the reactor 1L of the twelfth embodiment is provided with a П-shaped recess 31Fr across its upper surface, left and right opposing surfaces, and a corner portion connecting these. Each of the inner core protrusions 31Fs, 31Fs of the reactor of the thirteenth embodiment is provided with a П-shaped recess 31Fr over the upper surface, a part of the left and right opposing surfaces, and the upper corner portion connecting them. The other U-shaped concave portion 31Fr is provided across the lower surface, the other portions of the left and right opposing surfaces, and the lower corner portion connecting them.

As shown in FIGS. 31 and 32, the center of one unfoamed resin sheet 400П (FIG. 31) or two unfoamed resin sheets 400П and 400U (FIG. 32) along the recess 31Fr. A part is arranged on the upper surface or the lower surface of the recess 31Fr, and both sides thereof are arranged on the left and right surfaces of the recess 31Fr, respectively, and then foamed, thereby forming a coil fixing part having the inner interposition part. The unfoamed resin sheets 400 П and 400 U preferably have excellent flexibility so that they can be easily bent along the recesses 31 Fr in addition to having adhesiveness.

The reactors of the twelfth and thirteenth embodiments are excellent in manufacturability from the following points.
-In the manufacturing process, the number of unfoamed resin sheets used for the inner core portion 31F is less than that of the seventh embodiment, and the number of arrangement steps can be reduced.-Although the unfoamed resin sheet is relatively large, it has a rectangular parallelepiped shape. The resin sheet can be routed and arranged from the upper side or the lower side of the inner core protrusion 31Fs, and the outer core 32Fo exists outside the inner core protrusion 31Fs, but can be easily arranged

Further, in the reactors of the twelfth and thirteenth embodiments, although the number of unfoamed resin sheets is small, there are a plurality of flat portions in the inner peripheral space, and there are coil fixing portions including left and right facing positions. The coil 2 can be firmly fixed. In the reactor according to the thirteenth embodiment, since the coil fixing portion further includes the upper and lower opposing positions, the coil 2 can be fixed more firmly.

In addition, regarding the arrangement of the coil fixing portions in the twelfth embodiment, the three flat portions of the rectangular cylindrical inner space can be the lower side and the left and right sides. Even in this case, as described above, the number of unfoamed resin sheets is small, and the coil 2 can be firmly fixed.

[Modification 3]
In the third to eighth embodiments and the tenth to thirteenth embodiments, the form in which the magnetic core is not provided with the resin mold portion has been described. Even when the core pieces 33m and 34m are made of a composite material, a resin mold portion can be provided. In this case, since the composite material includes the surface resin layer as described above, the insulation between the coil and the magnetic core is excellent even if the resin mold portion is thinned. The resin mold part can be made small by making it thin.

In the form including the resin mold portion, for example, a form including four core parts as in the first embodiment, a form including a total of two core parts as in the modified example 1-2, and embodiments 2-1 and 2-1. Various configurations such as a form in which the resin mold portion is formed in two steps as in -2.

In addition, as in Embodiment 2-1, a form in which the resin mold part is provided with a recess, a form in which a part of the composite material is exposed from the resin mold part, and a recess using this exposed region is provided (Similar form as Embodiment 2) -2), Embodiment 2-1 / Embodiment 2-2 / Embodiments 5, 7, etc. combined, that is, the inner core part has a resin mold part with a recess, the resin mold part and the middle body part And the like, and the middle body portion itself has a concave portion.

[Embodiment 14]
The reactors of the modified examples such as the reactors 1A to 1J, 1L, and 1b of Embodiments 1 to 13 described above have, for example, maximum current (DC): about 100A to 1000A, average voltage: about 100V to 1000V, operating frequency : It can be used for a component of a converter mounted on a vehicle such as an electric vehicle or a hybrid vehicle, or a component of a power converter equipped with this converter, typically for applications of about 5 kHz to 100 kHz.

As shown in FIG. 33, a vehicle 1200 such as a hybrid vehicle or an electric vehicle is used for traveling by being driven by a main battery 1210, a power converter 1100 connected to the main battery 1210, and power supplied from the main battery 1210. Motor (load) 1220. The motor 1220 is typically a three-phase AC motor, which drives the wheel 1250 when traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, vehicle 1200 includes an engine in addition to motor 1220. In FIG. 33, an inlet is shown as a charging location of the vehicle 1200, but a form including a plug may be employed.

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

As shown in FIG. 34, the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor L, and converts input voltage by ON / OFF repetition (switching operation). (In this case, step-up / down pressure) is performed. As the switching element 1111, a power device such as a field effect transistor (FET) or an insulated gate bipolar transistor (IGBT) is used. The reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that prevents the change of the current to flow through the circuit. As the reactor L, any one of the reactors of modified examples such as the reactors 1A to 1J, 1L, and 1b of the first to thirteenth embodiments is provided. In particular, when a cooling case in which a liquid refrigerant flows in the converter 1110 is provided, the reactor L can be effectively cooled by storing the reactor L in the cooling case. The power conversion device 1100 and the converter 1110 include the reactors 1A to 1J, 1L, and 1b that can suppress the movement of the coils 2 and 2F, thereby suppressing the movement of the coils 2 and 2F.

In addition to converter 1110, vehicle 1200 is connected to power supply device converter 1150 connected to main battery 1210, sub-battery 1230 serving as a power source for auxiliary devices 1240, and main battery 1210. Auxiliary power converter 1160 for converting to low voltage is provided. The converter 1110 typically performs DC-DC conversion, while the power supply device converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Note that some of the power supply device converters 1150 perform DC-DC conversion. The reactors of the power supply device converter 1150 and the auxiliary power supply converter 1160 have the same configuration as any of the reactors 1A to 1J, 1L, and 1b of the first to thirteenth embodiments and the reactors of the modified examples. Reactor with modified can be used. In addition, any one of the reactors 1A to 1J, 1L, and 1b of the first to thirteenth embodiments and the reactor of the modified example may be used as a reactor that performs conversion of input power and that only performs step-up or step-down conversion. It is also possible to use.

In addition, this invention is not limited to these illustrations, is shown by the claim, and it is intended that all the changes within the meaning and range equivalent to the claim are included.

The reactor of the present invention includes various on-vehicle converters (typically DC-DC converters) mounted on vehicles such as hybrid vehicles, plug-in hybrid vehicles, electric vehicles, and fuel cell vehicles, and converters for air conditioners. It can utilize suitably for the component of a converter and a power converter.

1A to 1J, 1L, 1b Reactor 10 Combination 2, 2F Coil 2a, 2b, 2c Winding part 2r Coupling part 2w Winding 2e End 2t Turn 3A, 3B, 3C, 3F, 3b Magnetic core 310A, 310B Inner core Parts 320 Outer core parts 31 Middle body part 31e End face 31m, 32m, 33m, 34m Core piece 31g Gap material 32 Side body part 32e Inner end face 310m Middle resin mold part 320m Side resin mold part 310r, 312r, 31r, 31Fr Concave part 3120 Bottom hole 3122 Groove portion 310g Gap portion 310e End surface 320e Inner end surface 315 Frame portion 315h Through-hole 3150 Projection 3152 Projection plate portion 3154 Flat plate portion 3156 Partition plate 3158 Tube portion 3159 Rib 325 Mounting portion 325h Bolt hole 327 Finish Cut portion 31C, 31F Inner core portion 32C, 32F Outer core portion 31Cs, 31Fs Inner core protrusion 32Fr Connection portion 32Fo Outer peripheral portion 4 Coil fixing portion 40 Inner interposition portion 42 Turn interposition portion 44 End portion fixing portion 400, 400L, 400П, 400 Γ Unfoamed resin sheet 400 ￢, 400 [, 400] Unfoamed resin sheet 7 Sensor 75 Sensor holding unit 1100 Power converter 1110 Converter 1111 Switching element 1112 Drive circuit L Reactor 1120 Inverter 1150 Power supply converter 1160 Auxiliary power supply Converter 1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub battery 1240 Auxiliaries 1250 Wheel

Claims (11)

A coil formed by winding a winding spirally;
A magnetic core having an inner core portion disposed in the coil;
A coil fixing part that has a foamed resin and regulates the movement of the coil by volume expansion of the foamed resin;
The coil fixing portion includes a reactor including an inner interposed portion interposed between an inner peripheral surface of the coil and an outer peripheral surface of the inner core portion, and a turn interposed portion interposed between the turns of the coil. The reactor according to claim 1, wherein the inner core portion includes a recess in which the foamed resin is disposed. The inner core portion includes a middle main body portion serving as a magnetic path, and a middle resin mold portion covering at least a part of the outer peripheral surface of the middle main body portion,
The reactor according to claim 2, wherein the concave portion is provided in the middle resin mold portion. The inner core portion includes a middle main body portion serving as a magnetic path, and a middle resin mold portion covering a part of the outer peripheral surface of the middle main body portion,
A bottomed hole including an inner wall portion made of a constituent resin of the middle resin mold portion surrounding the exposed portion is formed with the exposed portion not covered by the middle resin mold portion in the middle main body portion as a bottom portion,
The reactor according to claim 2, wherein the recess includes the bottomed hole. The middle resin mold part is provided with a groove part having a groove bottom part continuous with the opening edge of the bottomed hole,
The reactor according to claim 4, wherein the concave portion includes the bottomed hole and the groove portion. The inner core portion includes a middle main body portion serving as a magnetic path,
The reactor according to claim 2, wherein the recess is provided in the middle main body. The reactor according to any one of claims 1 to 6, wherein the inner interposition part is provided over the entire length of the inner core part. The reactor according to any one of claims 1 to 7, wherein the turn interposition part is interposed in an area between the turns of the coil and does not reach the outer peripheral surface of the coil. The inner core portion includes a middle main body portion serving as a magnetic path, and a middle resin mold portion covering at least a part of the outer peripheral surface of the middle main body portion,
The reactor according to any one of claims 1 to 8, wherein at least a part of the coil fixing portion is provided in contact with the middle resin mold portion. The reactor according to any one of claims 1 to 9, wherein the inner core portion includes a composite material including a soft magnetic powder and a resin. The reactor according to claim 10, wherein the coil fixing portion is provided in contact with the composite material.

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