JP2010045111A - Reactor assembly - Google Patents

Abstract

A reactor assembly that can perform soft switching in addition to step-up and step-down operations, has a small number of parts, and is excellent in assembly workability.
A reactor assembly 1A includes a coil 11 formed by winding a winding 11w, a smoothing reactor (main reactor) 2A having a ring core 10 on which the coil 11 is disposed, and a cylindrical core 30. A resonance reactor (secondary reactor) 3A is provided. One end side of the winding 11w forming the coil 11 is extended, and the cylindrical core 30 is disposed so as to cover the outer periphery of the extended portion (crossover portion 11c). Terminal members 14a, 14b, and 14c are attached to both ends 11e of the winding 11w and intermediate portions of the crossover portion 11c, respectively. By using the winding 11w and the terminal member 14b in common for both reactors 2A and 3A, it is possible to reduce the number of components and the work of attaching the terminal member.
[Selection] Figure 1

Description

  The present invention relates to a reactor assembly suitable for a component part of a power conversion device such as an in-vehicle DC-DC converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor assembly having a small number of parts and excellent assembly workability.

  As a vehicle-mounted component such as a hybrid vehicle or an electric vehicle that uses a motor as a drive source or a power generation source during regeneration, there is a power conversion device that performs a step-up operation or a step-down operation between the motor and the power source. Generally, a power converter includes a converter that changes the magnitude of DC power and an inverter that converts DC power and AC power to each other.

  A converter usually includes a switching element such as a transistor that performs an ON / OFF switching operation, a smoothing reactor (inductor) that smoothes an AC current generated by the switching operation, and a capacitor that smoothes the generated AC voltage. Yeah. In recent years, power supplies provided in hybrid vehicles and the like have been studied to reduce the size of components by increasing the frequency. Since the switching operation increases the switching loss when the frequency is increased, soft switching with less switching loss is desired so that the loss can be reduced. Therefore, a converter including a resonance circuit so as to perform soft switching has been studied (Patent Documents 1 and 2). The resonance circuit is a series circuit including a resonance switching element and a resonance reactor, and is connected in parallel to the smoothing reactor.

  As a smoothing reactor, a reactor L including an annular core 100 made of a magnetic material and a coil 110 formed by winding a winding 111 and disposed on the outer periphery of the annular core 100 as shown in FIG. Representative. A combined body of the annular core 100 and the coil 110 is housed in the reactor case 120 and is integrally fixed by the potting resin 130 filled in the case 120 (FIG. 5B). A resonance reactor (not shown) includes an annular core and a coil composed of a winding wound around the core, a coil composed of a winding wound in a cylindrical shape, and a cylindrical space formed by the coil. And those having an EE type core and an EI type core disposed on the outer periphery of the coil.

  Each end portion 111e of the winding forming the smoothing reactor and the resonance reactor coil is usually provided with terminal members 140a and 140b, and connected to an external device such as a power source through the terminal members 140a and 140b. . Moreover, both reactors are connected using fixing members, such as a terminal member and a volt | bolt.

Japanese Unexamined Patent Publication No. 07-241072 JP2003-033013

  When soft switching is performed using the above conventional reactor, (1) work of winding a coil for the production of both a smoothing reactor and a resonant reactor, and (2) a terminal at each end of the total of four coils. The operation | work which attaches a member and the operation | work which connects (3) terminal members with a volt | bolt etc. are required. Therefore, there are problems that the number of parts is large and assembly workability is poor.

  Therefore, an object of the present invention is to provide a reactor assembly that can perform soft switching, has a small number of parts, and is excellent in assembly workability.

  The present invention is a configuration in which a part of the winding forming the coil of the smoothing reactor is used for the resonance reactor, that is, the configuration in which the winding forming one coil is shared by the two reactors. Achieve the goal. Specifically, the reactor assembly of the present invention includes a main reactor having a coil formed by winding a winding, an annular core on which the coil is disposed, and a sub-reactor having a cylindrical core. The winding forming the coil has an extended portion whose one end is extended. And the said cylindrical core is arrange | positioned so that the outer periphery of the said extension part may be covered.

  As a resonance reactor, as shown in FIG. 4 (A), a cylindrical core 30 made of a magnetic material is arranged so as to cover the outer periphery of a linear conductor (wiring) 40, and the conductor 40 functions as an inductance component. With this configuration, the winding work of the winding can be omitted. However, in this configuration, terminal members 141 and 142 are separately attached to both ends of the conductor 40 as shown in FIG. 4 (A), and one terminal member (for example, the terminal member 141) is shown in FIG. It is necessary to connect to one terminal member (for example, the terminal member 140b) of the smoothing reactor L. Therefore, the number of terminal members is the same as before, and connection work is also required.

  On the other hand, the reactor assembly of the present invention causes the extension part of the winding forming the coil included in the main reactor to function as the inductance component of the sub reactor. That is, in the configuration of the present invention, the windings of both reactors are continuous. Therefore, in the configuration of the present invention, the location where the terminal member is attached to both the reactors from the conventional four locations, one end portion extended in the winding forming the coil, both the other end portion of the winding, and the above It can be reduced to a total of 3 locations in the middle of the extension. The terminal member attached to the intermediate portion of the extended portion is used in common for both the smoothing reactor and the resonance reactor. Therefore, in the configuration of the present invention, it is necessary to attach a total of four terminal members to the ends of the windings of both reactors as in the conventional reactor and the configuration shown in FIG. 4, and connect one terminal member of each reactor among them. There is no. Further, in the configuration of the present invention, it is not necessary to form a coil by winding a winding as in a conventional resonance reactor.

  According to the reactor assembly of the present invention having the above configuration, (1) the winding work can be reduced, (2) the number of terminal members, the number of bolts connecting both the reactors, and the like can be reduced. ) It is possible to reduce the installation work of the terminal member, and there are various effects that the work of connecting the two reactors with bolts or the like is unnecessary, and (4) the formation of the sub-reactor is easy. Therefore, the reactor assembly of the present invention can perform soft switching by using the main reactor as the smoothing reactor and the sub reactor as the resonance reactor, and can reduce the number of parts and improve the assembly workability. Can be achieved.

  The reactor assembly of the present invention can be configured to include three terminal members. The three terminal members are a first terminal member connected to the other end of the winding, a second terminal member connected to the intermediate portion of the extension portion in the winding, and an end portion extended in the winding. A third terminal member to be connected is mentioned. In this embodiment, the cylindrical core is disposed between the second terminal member and the third terminal member.

  According to the above configuration, the coil that exists between the first terminal member and the second terminal member functions as an inductance component of the main reactor by attaching the second terminal member to the extended portion of the winding. And the extension part of the coil | winding which exists in a 2nd terminal member and a 3rd terminal member functions as an inductance component of a sub reactor. Thus, by attaching the second terminal member to the extension portion of the winding and disposing the cylindrical core in the extension portion, the smoothing reactor and the resonance reactor can be easily formed.

  In the reactor assembly of the present invention, the cylindrical core can be configured in a cylindrical shape by combining a pair of half cracked pieces. In particular, it is preferable that the pair of half-cut pieces are accommodated in an openable / closable core case so that the joint surfaces of the half-cut pieces open and close corresponding to the opening and closing of the case.

  According to the above configuration, when the core case is opened, the space between the half cracks also opens, so it is possible to insert the winding (extension part) from this opening and place the winding (extension part) in the recess of the half crack piece When the core case is closed, the space between the half cracks is also closed, so that the winding (extended portion) disposed in the recess can be maintained through the cylindrical core. That is, according to the said structure, a cylindrical core can be automatically arrange | positioned on the outer periphery of the extension part of a coil | winding by assembling a core case, and it is excellent in the assembly workability | operativity of a reactor assembly. Moreover, by storing the cylindrical core in the core case, the core can be mechanically protected and the weather resistance can be improved. Furthermore, since a pair of half-breaking pieces can be handled integrally by one core case, the above configuration is excellent in handling properties.

  In the reactor assembly of the present invention, the main reactor and the sub-reactor are housed in one reactor case, and both the reactors can be integrally molded with a resin.

  According to the said structure, the position of the cylindrical core in a sub reactor and the coil | winding (extension part) inserted in this core can be fixed with a resin mold. Therefore, not only can the desired characteristics of the sub-reactor be stably obtained, but a member for fixing the position need not be prepared separately, and the number of parts can be reduced and the fixing operation can be omitted. Moreover, the installation space can also be reduced by arrange | positioning both reactors so that it can accommodate in one reactor case. In addition, this configuration has (1) two reactors can be handled as one body, so it has excellent handling characteristics. (2) Both reactors are fixed by fixing the reactor case to the cooling base. (3) The core can be reinforced by the reactor case and resin mold, and the core, coil, and winding extension can be protected from the external environment. (4) The coil and the surrounding members can be protected by the mold resin. Insulation can be ensured, (5) Noise can be suppressed by molding resin, (6) Heat dissipation can be improved by using reactor case and molding resin for heat dissipation path, etc. Can do.

  In the reactor assembly of the present invention, the main reactor is housed in a reactor case, and the core case may be provided with a fixing piece for fixing to the reactor case.

  According to the above configuration, by fixing the core case to the reactor case, the position of the cylindrical core in the sub reactor and the winding (extension portion) inserted into the core can be fixed, and the desired characteristics of the sub reactor can be obtained. Obtained stably. In addition, the secondary reactor can be fixed at an arbitrary position of the reactor case by appropriately extending one end side of the winding of the main reactor and routing it to a desired position. Is expensive. Further, since the main reactor is housed in the reactor case, as described above, effects such as reinforcement of the core, protection from the external environment, and improvement of heat dissipation can be achieved.

  The reactor assembly of the present invention can be used as a component part of a power conversion device that performs soft switching in addition to step-up and step-down operations, has a small number of parts, and is excellent in assembly workability.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
<Embodiment 1>
1 (A) and 1 (B) are schematic perspective views of the reactor assembly of the present invention, (A) is a combination of a core and a coil, and (B) is a case where this combination is stored in a case. FIG. 1 (C) is a circuit diagram of the reactor assembly of the present invention. Hereinafter, the same reference numerals in the drawings indicate the same names.

  Reactor assembly 1A includes a smoothing reactor (main reactor) 2A and a resonance reactor (sub-reactor) 3A. For example, the smoothing reactor 2A smoothes an alternating current generated by a switching operation of a switching element included in the converter. The resonance reactor 3A is used for soft switching in order to reduce the loss of the switching operation. The reactor assembly 1A is characterized in that a part of the winding 11w forming the coil 11 of the smoothing reactor 2A is used as an inductance component of the resonance reactor 3A. Hereinafter, each configuration will be described in more detail.

[Smoothing reactor]
The smoothing reactor 2A includes an annular core 10 and a coil 11 disposed in a coil winding portion of the core 10.

  The annular core 10 includes a pair of rectangular parallelepiped coil winding portions and a pair of end cores 10e where the coil 11 is not disposed, and the end core 10e so as to sandwich the coil winding portions disposed separately from each other. Are arranged to form a closed loop. The annular core 10 includes a magnetic body portion 10m made of a soft magnetic material containing iron such as iron or steel and a gap material (not shown) made of a nonmagnetic material such as alumina. The magnetic body portion 10m is configured by combining a plurality of core pieces. In particular, the coil winding portion is configured by alternately laminating core pieces and gap materials. Each core piece can be a soft magnetic powder compact or a laminate of a plurality of electromagnetic steel plates. A gap material is a member arrange | positioned in the clearance gap provided between core pieces for adjustment of an inductance. The core piece and the gap material are integrally joined with an adhesive or the like. The number of core pieces divided and the number of gap members can be appropriately selected so that the smoothing reactor 2A has a desired inductance.

  The coil 11 is formed by winding a single continuous winding 11w and includes a pair of coil elements arranged in parallel. The winding 11w is a coated wire having an enamel coating on the surface of a copper rectangular wire. Both coil elements are formed by winding this covered wire edgewise, and are connected by a winding portion 11r. In addition to the above-described rectangular wire, the winding 11w can have various cross-sections such as a circular shape and a polygonal shape.

  One end side of the winding forming the coil 11 is extended, and in this extended portion (hereinafter referred to as the crossover portion 11c), the cylindrical core 30 constituting the resonance reactor 3A is disposed, and the crossover portion The point that the terminal member (second terminal member) 14b is attached to 11c is the greatest feature of the reactor assembly 1A.

  The transition portion 11c is formed by bending and extending one end side of the winding 11w as follows. The winding 11w is extended from the turn forming surface (upper surface) of the coil 11 upward in the direction orthogonal to the axial direction of the coil, and is extended by flatwise bending in the axial direction and away from the turn portion. Next, the winding 11w is extended by being flatwise bent downward in the orthogonal direction until it is substantially in the same position as the turn forming surface (lower surface) of the coil. Then, the crossing portion 11c is formed by flatwise bending the axial direction away from the turn portion and further extending the winding 11w. In the transition portion 11c, a portion in the vicinity of the coil 11 (a portion from the turn portion to the joint portion of the terminal member 14b) is mainly used for the energizing path of the smoothing reactor 2A.

  The combination of the annular core 10 and the coil 11 is also provided with an insulator. The insulator includes a cylindrical portion (not shown) that covers the outer periphery of the coil winding portion, and a frame-like portion 16 that comes into contact with the end surface of the coil 11 (the surface in which the coil turns appear to be annular). The cylindrical portion can easily cover the outer periphery of the coil winding portion by engaging the half-broken square tube pieces. The frame-shaped portion 16 is a pair of rectangular frames that are disposed opposite to both end portions of the cylindrical portion and abut against the end surface of the coil 11. For the insulator, an insulating material such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP) can be used.

[Reactor case]
The combination of the annular core 10 and the coil 11 is accommodated in an aluminum reactor case 12A. The reactor case 12A is filled with a potting resin 13, and the combined body is covered with the resin 13 except for the transition part 11c and the other end part 11e of the winding 11. As the potting resin, an epoxy resin, a urethane resin, or a silicone resin can be used.

  In order to fix the annular core 10 to the reactor case 12A, a tightening member such as a bolt may be used. The through hole through which the bolt passes may be provided in the end core 10e or in a fixing stay disposed on the upper surface of the end core 10e. In the former case, no fixing stay is required and the number of parts is small. In the latter case, the magnetic characteristics are not disturbed due to the through-holes provided in the annular core 10.

[Resonator for resonance]
The resonance reactor 3A includes a cylindrical core 30 and the above-described transition part 11c.

  2A and 2B are schematic perspective views of the cylindrical core. FIG. 2A shows a state where the cylindrical core is exposed without being stored in the core case, and FIG. 2B shows a state where the cylindrical core is stored in the core case. The cylindrical core 30 has a hollow cylindrical shape having a hollow portion penetrating from one opening portion to the other opening portion, and is formed into a cylindrical shape by combining a pair of semi-cylindrical (saddle-shaped) half crack pieces 31a and 31b. Composed. Since the outer shape of the cylindrical core 30 and the shape of the hollow portion are cylindrical, the magnetic characteristics are excellent. The size (thickness, length, outer diameter, and inner diameter of the hollow portion) of the cylindrical core 30 can be appropriately selected so as to obtain desired magnetic characteristics. The hollow portion has such a size that the crossing portion 11c can be inserted therethrough.

  The half crack pieces 31a and 31b are also made of a soft magnetic material. In particular, ferrite (sintered complex oxide containing ferric oxide) has excellent magnetic properties at high frequencies, so it has low core loss in high frequency bands, such as 10 kHz or more, and more than 100 kHz, and is a constituent material for high-frequency circuits. It can be suitably used. Moreover, ferrite is relatively inexpensive and excellent in economic efficiency.

  A gap material 32 made of an alumina plate is interposed between the two joining surfaces of the half-splitting pieces 31a and 31b, and the two gap materials 32 maintain a state in which a predetermined gap exists between the joining surfaces. The The gap material 32 is fixed to the joint surface of one half-cracked piece (here, half-cracked piece 31b) with an adhesive.

  Half-broken pieces 31a and 31b are housed in a core case 33 made of an insulating resin. The core case 33 includes divided bodies 33a and 33b that respectively store the half-broken pieces 31a and 31b. Each of the divided bodies 33a and 33b has a semi-cylindrical shape (a bowl shape) along the outer shape of the half crack piece, and exposes the joint surface of one half crack piece (here, the half crack piece 31a) and the gap member 32. The other parts are not exposed. With this configuration, when the divided bodies 33a and 33b are assembled so as to have a cylindrical shape, the joint surface of the half crack piece 31a and the gap material 32 are joined, and the cylindrical core 30 having the gap material 32 is assembled. In particular, the core case 33 has a part of the divided bodies 33a and 33b, specifically, one of the outer edges at the edge along the axial direction of the hollow part connected by the connecting part 33c, and the other outer edge. The part side can be opened freely. That is, as shown in FIG. 2 (B), the core case 33 is C-shaped when the divided bodies 33a and 33b are opened. Further, the core case 33 has engaging portions (not shown) integrally formed with each of the divided bodies 33a and 33b so that this state can be maintained when the core case 33 is closed so as to have a cylindrical shape. Instead of the engaging portion, a cylindrical state may be maintained using a fastening band, a bolt / nut, or the like. By using the engaging portion or the like, the half-cracked pieces 31a and 31b can be joined and held in a cylindrical shape without using an adhesive or a fastening body.

  Further, the core case 33 includes a flange portion (fixed piece) 34 disposed on the outer periphery of the divided body 33a so as to extend in the tangential direction so that the cylindrical core 30 can be fixed to the reactor case 12A. The flange portion 34 has a plate shape and includes a bolt hole 34h through which a fixing bolt (not shown) is passed. Here, the flange portion 34 is fixed to the outer periphery of the divided body 33a at a position shifted by 90 ° from the joint surface so that the flange portion 34 does not hinder the opening / closing operation.

  The cylindrical core 30 housed in the core case 33 is disposed on the outer periphery of the transition portion 11c so that the transition portion 11c of the winding connected to the coil 11 of the smoothing reactor 2A is inserted through the hollow portion. . Then, the resonance reactor 3A is configured by causing the crossover portion 11c to function as an inductance component.

[Terminal materials]
Both ends of the winding 11w, that is, one end (one end) 11e that is extended, the other end (the other end) 11e that is not extended, and a transition portion 11c that is an extension of the winding 11w Terminal members 14c, 14a, and 14b are respectively attached to the intermediate portions. Each of the terminal members 14a, 14b, and 14c is a conductive member to which an external device (not shown) such as a power source that supplies power to the coil 11 and the crossing portion 11c is connected, and wiring (not shown) connected to the external device. Since the terminal portion of (1) is attached by a bolt (not shown), it has a bolt hole 14h. Each terminal member 14a, 14b, 14c has a joint where the winding 11w is welded. For welding, for example, TIG welding can be suitably used.

  The terminal members 14a and 14b have a bent shape in which the conductive plate is bent stepwise, and further, one end side is bent back vertically, and the one end side that is turned back is the joining portion of the winding 11w, and the other end side is the bolt hole 14h. It is the formation place. These terminal members 14a and 14b are integrated with a terminal block 15 made of an insulating resin. The terminal block 15 has a bolt hole 15h at a position matching the bolt hole 14h of the terminal members 14a and 14b. This terminal block 15 is fixed to the reactor case 12A. The terminal member 14c is a conductive plate having a bolt hole 14h at the center.

[Assembly of reactor assembly]
A reactor assembly having the above configuration can be formed as follows.

First, an assembly of the annular core 10 and the coil 11 is formed.
A core piece and a gap material are fixed with an adhesive or the like to form a coil winding portion, an insulator (tubular portion) is disposed on the outer periphery, and a coil 11 is disposed on the outer periphery. The coil 11 is prepared separately by winding the winding 11w. In addition, a transition portion 11c having a predetermined shape is formed. The frame-shaped portion 16 and the end core 10e are arranged on the coil 11 so that the end surface of the coil 11 is sandwiched between the insulator (frame-shaped portion 16) and the end core 10e, and the end core 10e and the coil are wound with an adhesive or the like. Join the parts to form an union.

  Next, after storing the combined body in the reactor case 12A, the potting resin 13 is filled in the case 12A. At this time, the crossover portion 11c and the other end portion 11e of the winding 11 are exposed from the potting resin 13, as shown in FIG. Further, after filling the potting resin 13, the terminal block 15 is attached to the reactor case 12A. Note that the potting resin 13 may be filled after the terminal block 15 is attached to the reactor case 12A.

  Next, the joint portion of the terminal members 14a, 14b, and 14c, the both end portions 11e of the winding, and a part of the crossover portion 11c are welded.

  Then, the cylindrical core 30 is attached to the winding transition part 11c. Specifically, the core case 33 is opened, the cylindrical core 30 is disposed so as to cover the crossing portion 11c with the concave portions of the two divided bodies 33a and 33b (half-fragment pieces 31a and 31b), and then the case 33 is closed. Thereafter, a bolt is screwed into the flange portion 34, and the core case 33 is fixed to the reactor case 12A. The reactor assembly 1A is assembled by the above process.

[effect]
The reactor assembly 1A having the above-described configuration can reduce the number of parts by using the winding 11w constituting the coil 11 provided in the smoothing reactor 2A in common for the resonance reactor 3A (FIG. 1). (C)). In addition, the reactor assembly 1A includes the winding reactor 11A and the cylindrical core 30 to form the resonance reactor 3A, thereby reducing winding winding work and terminal member mounting work. It is possible to perform the assembly workability.

  In particular, the cylindrical core 30 shown in this embodiment is a combination of a pair of half-broken pieces 31a and 31b, and is housed in a core case 33 that can be freely opened and closed. Is easy to arrange. In addition, since the cylindrical core 30 includes the gap member 32, desired magnetic characteristics can be easily controlled. Further, the cylindrical core 30 is housed in a core case 33 made of an insulating material, so that the insulation with the winding 11 can be enhanced and the mechanical protection can be achieved. In addition, by providing the core case 33 with the flange portion 34, the cylindrical core 30 can be easily fixed to the reactor case 12A using an adhesive, a screw, or the like. By this fixing, the cylindrical core 30 is not displaced in the longitudinal direction of the winding 11 (crossover portion 11c), and desired characteristics can be stably obtained.

  In addition, the reactor assembly 1A is configured such that the combination of the annular core 10 and the coil 11 is housed in the reactor case 12A and sealed with the potting resin 13, thereby reinforcing the core 10 and from the external environment of the combination. There are various effects such as protection, improvement of insulation between the coil 11 and surrounding members, reduction of noise due to vibration, and improvement of heat dissipation.

<Modification 1-1>
In Embodiment 1, the cylindrical core 30 housed in the core case 33 has been described, but the core case 33 may be omitted. In this case, the two pieces 31a and 31b are arranged at predetermined positions of the crossover portion 11c so as to cover the outer periphery of the crossover portion 11c with the concave portions (inner peripheral surfaces) of the half-split pieces 31a and 31b. The bonding surfaces are bonded with an adhesive. Instead of adhesive, use a fastening band, or provide bolt holes in places where there is little influence on the magnetic properties of each half-cracked piece 31a, 31b, and use bolts and nuts to attach both pieces 31a, 31b. It may be integrated. In addition, when the core case 33 is omitted, the insulation between the cylindrical core 30 can be obtained by covering the outer periphery of the transition portion 11c with an insulating material (not shown) such as an insulating sheet or paper, or by disposing an insulating bobbin. Can be enhanced. The cylindrical core 30 disposed on the outer periphery of the transition portion 11c is attached to the reactor case 12A using, for example, a fixture (not shown) having a flange portion so as not to be displaced in the longitudinal direction of the transition portion 11c. Fix it. The flange portion can be fixed to the case 12A by providing a screw hole in the flange portion and screwing the flange portion and the reactor case 12A or using an adhesive.

<Modification 1-2>
In the first embodiment, the cylindrical core 30 that has a cylindrical shape by combining a pair of half-broken pieces has been described. However, a cylindrical core that is integrally formed in a cylindrical shape or a part that is cut out like a C-shape is cut out. A cylindrical core having a different shape can be used. The integrally formed cylindrical core can be disposed on the outer periphery of the transition portion by inserting the terminal member into the transition portion before welding the terminal member to the end portion (one end portion of the winding) of the transition portion.

<Modification 1-3>
In the first embodiment, one cylindrical core 30 included in the resonance reactor is used. However, a configuration may be adopted in which a plurality of cylindrical cores are aggregated and desired magnetic properties are obtained by combining the aggregates. When the number of cylindrical cores is small, the preparation time of the cylindrical core and the arrangement time at the transition portion are short, and the assembly workability is excellent. On the other hand, when the resonance reactor is constituted by an assembly of a plurality of cylindrical cores, each cylindrical core can be made small, so that the degree of freedom of installation is large and the degree of freedom of the shape of the crossover portion is also large.

<Modification 1-4>
In the first embodiment, the configuration in which the cylindrical core 30 includes the gap material has been described. However, the gap may not be provided, or an air gap in which only air is present may be used. In the case of an air gap, a desired gap distance can be provided by fixing each half crack piece to the core case so that a desired gap is formed between the half crack pieces when both half pieces are combined. When a gap material is interposed, it is easy to maintain a desired gap distance.

<Modification 1-5>
In the first embodiment, the configuration in which the smoothing reactor 2A is housed in the reactor case 12A has been described, but the case 12A can be omitted. In this case, if the smoothing reactor 2A and the resonance reactor 3A are integrally molded with resin, both the reactors 2A and 3A can be handled integrally, and the mechanical protection and insulation of both reactors 2A and 3A are improved. Can be planned. For the resin mold, insulating resin, specifically, epoxy resin, urethane resin, PPS resin, polybutylene terephthalate (PBT) resin, acrylonitrile-butadiene-styrene (ABS) resin, or the like can be used. By omitting the reactor case, the reactor assembly can be further reduced in size.

  The configurations of these modified examples 1-1 to 1-5 can also be applied to a second embodiment described later.

<Embodiment 2>
FIG. 3 is a schematic perspective view of another reactor assembly of the present invention, in which (A) shows a combination of a core and a coil, and (B) shows a state in which this combination is housed in a case. Reactor assembly 1B differs from Embodiment 1 in that both smoothing reactor 2B and resonant reactor 3B are housed in reactor case 12B. Hereinafter, this point will be mainly described.

  The winding 11w constituting the coil 11 provided in the smoothing reactor 2B includes a transition portion 11Bc formed as follows on one end side. As shown in FIG. 3 (A), on one end side of the winding 11w, the winding 11w is extended upward from the turn forming surface (upper surface) of the coil 11 in the direction perpendicular to the axial direction of the coil (vertical direction in FIG. 3). The wire is stretched by flatwise bending in the axial direction and away from the turn portion, and further edgewise bent and stretched in a direction perpendicular to the axial direction (horizontal direction (left-right direction in FIG. 3)). Then, the winding 11w is extended by flatwise bending upward in the direction orthogonal to the axial direction (vertical direction), and further extended by flatwise bending and extending in the direction orthogonal to the axial direction (horizontal direction). Part 11Bc is formed. The cylindrical core 30 is disposed in an intermediate portion (portion in which the winding 11w extends in the horizontal direction) of the transition portion 11Bc. The cylindrical core 30 shown in this embodiment is housed in a core case 33 that does not have a flange portion.

  The terminal members 14a, 14b, and 14c are the same as those in the first embodiment, and the terminal members 14a and 14b shown in this embodiment have a joint portion with the other end portion 11e of the winding and a joint portion with the transition portion 11Bc. It is embedded in the potting resin 13 (FIG. 3B). That is, the smoothing reactor 2B is embedded in the potting resin 13 including the other end 11e of the winding. Further, in the resonance reactor 3B, in the terminal member 14c and the connecting portion 11Bc, the vicinity of the connection portion with the terminal member 14c (near one end portion 11e of the winding) is exposed from the potting resin 13, and the other portions are resin. Buried in 13

  The reactor case 12B has a size that can accommodate both the smoothing reactor 2B and the resonance reactor 3B.

  Such a reactor assembly 1B is assembled as follows. The procedure up to the production of the combination of the annular core 10 and the coil 11 is performed in the same manner as the procedure of the first embodiment described above. Next, the cylindrical core 30 is attached to the winding transition part 11Bc in the same manner as in the first embodiment. After the obtained assembly including the resonance reactor 3B is housed in the reactor case 12B, the joint portions of the terminal members 14a, 14b, and 14c, both ends 11e of the winding, and a part of the crossover portion 11Bc are welded. To do. The terminal block 15 is attached to the reactor case 12B before welding. Then, the potting resin 13 is filled in the reactor case 12B. The reactor assembly 1B is assembled by the above process.

  Reactor assembly 1B having the above configuration has the same effects as reactor assembly 1A of the first embodiment described above. In addition to the above-described effects, both the smoothing reactor 2B and the resonance reactor 3B are housed in one reactor case 12B, so that the two reactors 2B and 3B are unlikely to be separated. Therefore, the reactor assembly 1B is easy to handle and has excellent handling properties. In addition, since the resonance reactor 3B is integrated with the smoothing reactor 2B by the common potting resin 13, the cylindrical core 30 is not substantially displaced and stable characteristics can be obtained. Furthermore, by embedding both reactors 2B and 3B in potting resin 13, it can be mechanically protected. 1. Insulation between winding 11w (coil 11) and annular core 10 and cylindrical core 30 3. The joint strength of the welded portion between the winding 11w and the terminal member 14a can be increased.

  The above-described embodiment can be appropriately changed without departing from the gist of the present invention, and is not limited to the above-described configuration.

  The reactor assembly of the present invention can be suitably used for a component part of a power conversion device such as a converter mounted on a vehicle such as a hybrid vehicle or an electric vehicle. In particular, the present invention reactor assembly has a maximum current of 50 A or more and a carrier frequency of 10 kHz or more when the soft switching is desired in the bidirectional DC-DC converter included in the vehicle. It can be suitably used when the inductance of the resonance reactor is 5.0 μH or less.

(A), (B) is a perspective view showing an outline of the reactor assembly shown in Embodiment 1, (A) is a combination of a core and a coil, (B) is a reactor case (C) is a circuit diagram illustrating a connection state between the smoothing reactor and the resonance reactor. It is a perspective view which shows the outline of the cylindrical core provided in the reactor for resonance, (A) is a state in which a pair of half crack pieces are not stored in the core case, and (B) is a half case where these half crack pieces are the core case. The state stored in is shown. FIG. 5 is a perspective view schematically showing a reactor assembly shown in Embodiment 2, wherein (A) shows a combination of a core and a coil, and (B) shows a state in which the combination is housed in a reactor case. (A) is a schematic perspective view of a resonance reactor in which a cylindrical core is inserted through a linear conductor, and (B) is a circuit diagram illustrating a connection state between a smoothing reactor and a resonance reactor. . It is a perspective view which shows the outline of the conventional smoothing reactor, (A) is the combination of a core and a coil, (B) shows the state which accommodated this combination in the reactor case.

Explanation of symbols

1A, 1B Reactor assembly 2A, 2B Smoothing reactor
3A, 3B Resonant reactor
10 Ring core 10e End core 10m Magnetic body 11 Coil 11w Winding
11e Winding end 11c, 11Bc Crossover 11r Rewinding part
12A, 12B Reactor case 13 Potting resin 14a, 14b, 14c Terminal material
14h Bolt hole 15 Terminal block 15h Bolt hole 16 Frame
30 Cylindrical core 31a, 31b Half crack 32 Gap material 33 Core case
33a, 33b Divided body 33c Connection part 34 Flange part 34h Bolt hole
40 conductors
100 annular core 110 coil 111 winding 111e end of winding
120 Reactor case 130 Potting resin
140a, 140b, 141,142 Terminal member
L reactor

Claims (5)

A main reactor having a coil formed by winding a winding and an annular core on which the coil is disposed;
With a sub-reactor with a cylindrical core,
One end side of the coil | winding which forms the said coil is extended, The said cylindrical core is arrange | positioned so that the outer periphery of this extension part may be covered, The reactor assembly characterized by the above-mentioned. A first terminal member connected to the other end of the winding;
A second terminal member connected to an intermediate portion of the extension portion in the winding;
A third terminal member connected to one end extended in the winding,
2. The reactor assembly according to claim 1, wherein the cylindrical core is disposed between the second terminal member and the third terminal member. The cylindrical core is configured in a cylindrical shape by combining a pair of half-cracked pieces,
The half crack piece is stored in a core case that can be opened and closed,
3. The reactor according to claim 1 or 2, wherein the half case pieces are accommodated in the core case so that the joint surfaces of the half case pieces open and close corresponding to the opening and closing of the core case. Aggregation.   The reactor assembly according to any one of claims 1 to 3, wherein the main reactor and the sub reactor are housed in a single reactor case, and both the reactors are integrally molded with a resin. body. The main reactor is housed in a reactor case,
4. The reactor assembly according to claim 3, wherein the core case includes a fixing piece for fixing to the reactor case.

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