JP2012227288A - Coil formed body, component for reactor, and the reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil formed body which is suitable for forming a reactor, a component for the reactor including the coil formed body, and the reactor having excellent assembly workability.SOLUTION: A coil formed body 3 is used for a reactor 1 including a coil 3c formed by spirally winding a winding wire 3w and includes: an end part fixing jig 4; an axial length maintaining jig 5; and a shape holding member 6. The end part fixing jig 4 fixes both end parts 3e of the coil 3c and positions the positions of both the end parts 3e relative to each other. The axial length maintaining jig 5 maintains the coil 3c in a compressed state that the length is shorter than the free length of the coil 3c. The shape holding member 6 is made of an insulation material and covers at least a part of a surface of the coil 3c to hold the shape of the coil 3c. The end part fixing jig 4 and the axial length maintaining jig 5 are integrally fixed to the coil 3c by the shape holding member 6.

Description

  The present invention relates to a reactor used for a component of a power conversion device such as an in-vehicle DC-DC converter, a coil molded body suitable for the component of the reactor, and a reactor component. In particular, it is related with the coil molded object suitable for construction of a reactor.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. This reactor is used for a converter mounted on a vehicle such as a hybrid vehicle. As the reactor, for example, there is one shown in Patent Document 1.

  The reactor of Patent Document 1 includes one coil, a cylindrical inner core portion disposed on the inner periphery of the coil, a cylindrical core portion covering substantially the entire circumference of the outer peripheral surface of the coil, and each of the coils. A magnetic core having a pair of disk-shaped core portions arranged on the end face, that is, a so-called pot-type core is provided. In the pot-type core, an inner core portion and a cylindrical core portion arranged concentrically are connected by the disk-shaped core portion to form a closed magnetic circuit.

JP 2009-033051 A

  Usually, the coil before being assembled to the reactor is spring-backed simply by winding the winding, so that a space is easily formed between the winding turns. Since the shape of such a coil is not maintained, the length in the axial direction (axial length) of the coil cannot be kept constant, such as expansion and contraction. Positioning is also difficult. For this reason, handling of the coil is difficult, and there is a possibility that the assembly workability of the reactor is reduced.

  This invention is made | formed in view of said situation, and the one of the objectives is to provide the coil molded object suitable for construction of a reactor.

  Another object of the present invention is to provide a reactor component comprising the coil molded body.

  Another object of the present invention is to provide a reactor excellent in assembly workability.

  The coil molded body of the present invention is used for a reactor including a coil formed by winding a winding in a spiral shape, and includes an end fixing jig, an axial length maintaining jig, and a shape holding member. The end fixing jig fixes both ends of the coil and positions each other. The axial length maintaining jig maintains the coil in a compressed state shorter than the free length of the coil. The shape holding member is made of an insulating material and covers at least a part of the surface of the coil to hold the shape of the coil. The end fixing jig and the axial length maintaining jig are integrally fixed to the coil by the shape holding member.

  According to said structure, since a coil can be maintained by predetermined axial length with an axial length maintenance jig | tool, it can suppress that the axial length of the coil by springback changes. In addition, since both end portions of the winding constituting the coil can be fixed by the end fixing jig and the both end portions can be prevented from varying, positioning of the both end portions relative to each other is facilitated. Therefore, since handling of a coil becomes easy, it becomes easy to form a shape holding member in the outer periphery of a coil. Therefore, the said coil molded object can be utilized suitably for constructing a reactor.

  As one form of this invention coil forming object, it is mentioned that it is the integral molding jig | tool in which the said edge part fixing jig and the said axial length maintenance jig | tool are integrally formed.

  According to the above configuration, the axial length of the coil can be maintained at a desired length with a small number of parts, and the positions of both end portions of the coil can be fixed.

  As one form of this invention coil forming object, it is mentioned that the said edge part fixing jig and the said axial length maintenance jig | tool are separate members.

  According to said structure, since both said jig | tool is another member, it is easy to mount | wear each coil to a coil. In addition, it is possible to widen the options of locations where the axial length maintaining jig is disposed. Further, each jig can be easily manufactured because the shape corresponding to the individual function can be selected independently of the shape of the other jig.

  As one form of the coil molded body of the present invention, the axial length maintaining jig includes an end surface support portion that comes into contact with both end surfaces of the coil and a connection portion that connects the both end surface support portions. It is done. And the said connection part is provided with the through-hole, and is filled with the constituent material of the said shape maintenance member.

  According to said structure, it can make it easy to support a coil to a compression direction by the end surface support part contact | abutted to the both end surfaces of a coil. In addition, by providing the through hole, it is easy to spread the constituent material of the shape holding member even at the location where the axial length maintaining jig in the coil is disposed. Therefore, when the reactor is assembled, it is possible to ensure insulation between the coil and the magnetic core.

  The reactor component of the present invention includes the above-described coil molded body of the present invention and an inner core portion disposed in the coil of the coil molded body. And the said inner core part is integrally hold | maintained by the shape holding member of the said coil molded object.

  According to said structure, since the coil molded object with which handling of a coil is easy is provided, the components for reactors can be produced easily. In addition, since the inner core portion is integrally held by the shape holding member of the coil molded body, when assembling the reactor, the inner core portion and the coil molded body are not separated, so that the assembly work is not complicated. In addition, since it is not necessary to align the inner core portion and the coil molded body, the assembling work can be simplified. Therefore, the assembly workability of the reactor is excellent.

  As an embodiment of the reactor component according to the present invention, the inner core portion is formed by pressing a coated soft magnetic powder comprising a plurality of coated soft magnetic particles in which a soft magnetic particle is coated with an insulating coating. It is mentioned that.

  According to said structure, a complicated three-dimensional shape can be easily formed by making an inner core part into a compacting body.

  The reactor of the present invention includes the above-described coil molded body of the present invention, an inner core portion, an outer core portion, and a case. The inner core portion is disposed in the coil of the coil molded body. An outer core part is comprised with the mixture containing magnetic powder and resin, covers at least one part of the outer periphery of the said coil molded object, is connected with the said inner core part, and forms a closed magnetic circuit. The case houses a combination of the magnetic core having the inner core portion and the outer core portion and the coil molded body.

  According to said method, since the coil molded object of the said invention is provided, since handling of a coil does not become complicated, it is excellent in the assembly workability | operativity of a reactor.

  The reactor of the present invention includes the above-described reactor component of the present invention, an outer core portion, and a case. An outer core part is comprised with the mixture containing magnetic powder and resin, covers at least one part of the outer periphery of the said components for reactors, and is connected with the inner core part of the said components for reactors, and forms a closed magnetic circuit. The case accommodates an integral part of the reactor part and the outer core part.

  According to the above method, the reactor component is easy to handle the coil and has a small number of components, so that the assembly workability of the reactor is excellent.

  The coil molded body of the present invention is suitable for the construction of a reactor because the coil can be easily handled.

  The reactor component of the present invention is excellent in the assembly workability of the reactor because the coil molded body of the present invention and the inner core portion are integrated.

  The reactor of the present invention is excellent in assembling workability.

1 is a schematic perspective view showing a reactor according to Embodiment 1. FIG. It is a schematic perspective view which shows the components for reactors with which the reactor which concerns on Embodiment 1 is provided. FIG. 2 is an exploded perspective view showing an outline of constituent members of a coil molded body provided in the reactor according to the first embodiment. It is a disassembled perspective view which shows the outline of the structural member of the coil molded object with which the reactor which concerns on Embodiment 2 is provided. It is a schematic perspective view which shows the coil molded object with which the reactor which concerns on Embodiment 3 is provided.

  Hereinafter, an embodiment of a reactor of the present invention will be described with reference to the drawings. The same reference numerals in the figure indicate the same names.

Embodiment 1
[Reactor]
With reference to FIGS. 1-3, the reactor 1 of Embodiment 1 is demonstrated. As shown in FIG. 1, the reactor 1 includes a reactor part 2 including a coil molded body 3 and an inner core part 71, an outer core part 72 covering at least a part of the outer periphery of the reactor part 2, and a reactor A case 8 for housing an integral part of the component 2 and the outer core portion 72 is provided. One of the features of the reactor 1 of the present invention is that the coil molded body 3 of the reactor component 2 includes an end fixing jig 4 and an axial length maintaining jig 5. In this example, the axial length maintaining jig 5 is provided on the case opening side and the bottom surface side of the coil 3c so as to face the axis of the coil 3c (FIG. 3). The case opening side axial length maintaining jig 5u is an integrally formed jig integrally formed with the end fixing jig 4, and the bottom side axial length maintaining jig 5d is a separate member from the end fixing jig 4. It is. Hereinafter, each configuration will be described in detail.

[Reactor parts]
(Coil molding)
As shown in FIG. 2, the coil molded body 3 includes a coil 3 c, an end fixing jig 4, an axial length maintaining jig 5, and a shape holding member 6.

<coil>
The coil 3c is a cylindrical body formed by spirally winding one continuous winding 3w. The winding 3w is preferably a coated wire having an insulation coating made of an insulating material on the outer periphery of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof. The conductor may have various shapes such as a rectangular wire having a rectangular cross section, a circular wire having a circular shape, and a deformed wire having a polygonal shape. The insulating material constituting the insulating coating is typically an enamel material such as polyamideimide. The thickness of the insulating coating is preferably 20 μm or more and 100 μm or less, and the thicker the pinholes can be reduced, the higher the insulation. For example, when an enamel material is applied in multiple layers to form an insulating coating, the thickness of the insulating coating can be increased. The insulating coating can also be a multilayer structure made of different materials. For example, a multilayer structure having a polyphenylene sulfide layer on the outer periphery of the polyamideimide layer can be mentioned. Multi-layer insulation coatings are also excellent in electrical insulation. The number of turns (number of turns) can be selected as appropriate, and about 30 to 70 can be suitably used for in-vehicle components.

  Here, the coil 3c is a coated rectangular wire in which the conductor is made of copper, the cross-sectional shape is a rectangular rectangular wire (aspect ratio: width / thickness is 5 or more, preferably 10 or more), and the insulating coating is enamel. Are edgewise coils formed by edgewise winding.

  As shown in FIG. 3, the coil 3c has a shape in which an end surface 3e is formed of a curved portion and a straight portion. More specifically, the end face shape of the coil 3c is composed of a pair of linear portions 32 arranged in parallel and a pair of semicircular arc portions 31 arranged so as to connect the end portions of both linear portions 32. It is a racetrack. Here, the aspect ratio: major axis / minor axis of the coil 3c is about 1.3. Since the semicircular arc portion 31 has a relatively large bending radius and is a curved portion with a gentle bending, this end surface shape is a shape that can be easily edgewise wound. Due to the end face shape, the outer peripheral surface of the coil 3c is composed of a curved surface formed by the semicircular arc portion 31 and a plane formed by the straight portion 32.

  The coil 3c is housed in the case 8 in a state where a part of the magnetic core 7 (inner core portion 71) is inserted on the inner periphery thereof. In particular, the reactor 1 of the present invention has a horizontal arrangement in which the reactor 1 is housed in the case 8 so that the axial direction of the coil 3c is parallel to the surface of the installation target when the reactor 1 is installed on the installation target such as a cooling stand. At that time, a planar region formed by the linear portion 32 on the outer peripheral surface of the coil 3 c is arranged in parallel to the bottom surface of the case 8. The coil 3c is covered with the magnetic core 7 (outer core portion 72) except for the case 8 and the place where it is installed. Specifically, the outer core portion 72 covers the portion other than the installation surface of the case 8 in the shape holding member 6 that covers the outer periphery of the axial length maintaining jig 5d disposed on the bottom surface side of the case 8.

  Both end portions 3e of the winding 3w forming the coil 3c are appropriately extended from the turn and pulled out of the outer core portion 72, and the conductor portion exposed by peeling off the insulation coating is made of copper or aluminum. A terminal member (not shown) made of a conductive material is connected. An external device (not shown) such as a power source for supplying power is connected to the coil 3c through this terminal member. For connection between the conductor portion of the winding 3w and the terminal member, welding such as TIG welding, crimping, or the like can be used. In the example shown in FIG. 1, both end portions 3e of the winding 3w are drawn upward so as to be orthogonal to the axial direction of the coil 3c, but the drawing directions of both end portions can be selected as appropriate. For example, both end portions of the winding 3w may be drawn out so as to be parallel to the axial direction of the coil 3c, or the drawing directions of the respective end portions may be different.

  The coil 3c includes a pair of coil elements formed by spirally winding a single continuous winding 3w having no joint portion, and a coil coupling portion that couples both coil elements with a part of the winding 3w. It is good also as a form which provides. In that case, it is mentioned that both coil elements are arranged side by side in parallel so that the respective axial directions are parallel.

<End fixing jig>
The end fixing jig 4 is a member for fixing both ends 3e and 3e of the winding 3w constituting the coil 3c and positioning each other. The term “end” as used herein includes not only the case where the winding 3w is connected to the terminal member but also the case where the winding is drawn from the turn of the coil 3c. As a form thereof, for example, a form having a pair of gripping parts 40 that grip both ends 3e of the winding 3w and a connecting part that connects the gripping parts 40 to fix the gripping part 40 at a predetermined position. Is mentioned. In this example, the connecting portion 53u also serves as a connecting portion of an axial length maintaining jig 5u described later.

  The shape of the grip portion 40 may be any shape that can grip the end portion 3e of the winding 3w. Specifically, a cylindrical shape covering the entire outer periphery of the winding 3w may be used, or a shape in which a part of the cylindrical shape in the circumferential direction is open, specifically a C-shape may be used. In the former case, the end 3e of the winding 3w can be sufficiently grasped. In the latter case, it is easy to fit the winding 3w from the opening. In this example, as shown in FIG. 3, it is a substantially rectangular cylindrical body that covers the entire outer periphery of the end 3e of the winding 3w along the shape of the winding 3w. If it does so, the insulation distance with the outer core part 72 is fully securable over the perimeter of the coil | winding 3w.

  The connecting portion connects the gripping portions 40 to each other and fixes the gripping portions 40 at a desired interval. The shape of the connecting portion is not particularly limited and can be selected as appropriate. For example, a rectangular flat plate, a bar having a rectangular or circular cross section, and the like can be given.

  For example, when the coil 3c is viewed in plan, the connection portions 40 are connected to each other by the connecting portion, and the end portions 3e of the winding 3w are positioned diagonally with respect to the axial direction of the coil 3c as in this example. In this case, the gripping portions 40 may be connected in a straight line with an I-shaped connecting portion, or one side of the connecting portion bent in an L-shape is parallel to the axial direction of the coil 3c and the other side. The end portions 3e may be connected to each other in a direction perpendicular to the axis of the coil 3c. Further, when the end portions 3e of the winding 3w are located on a line parallel to the axis of the coil 3c, or located on a line orthogonal to the axis of the coil 3c, they are gripped by the I-shaped connection portion as described above. It is good also as a form which connects the parts 40 on a straight line, and when the coil 3c is planarly viewed, it is good also as a form connected with the connection part bent so that it might become a shape. In either case, the former form of connecting the shortest distance between the gripping portions 40 is preferable.

  In this example, the end fixing jig 4 and the axial length maintaining jig 5 are integrally formed, and the connecting portion serves as the connecting portion 53u of the axial length maintaining jig 5u. The end fixing jig 4 and the axial length maintaining jig 5 may be separate members. In that case, it is good to provide the connection part of the shape and connection form mentioned above. Here, the gripping portion 40 is fixed at a predetermined position by the connecting portion 53u so that the end portion 3e of the winding 3w can be fixed at a desired position.

  The constituent material of the end fixing jig 4 is preferably a material that is excellent in heat resistance to such an extent that it does not soften with respect to the maximum ultimate temperature of the coil. In addition, it is particularly preferable if the insulating property is excellent. Specifically, polyphenylene sulfide (PPS) resin, liquid crystal polymer (LCP), polytetrafluoroethylene (PTFE) resin, nylon 6 (registered trademark), nylon 66 (registered trademark), epoxy resin, acrylonitrile-butadiene-styrene ( An insulating resin such as an ABS resin can be preferably used.

<Axis length maintenance jig>
The axial length maintaining jig 5 is a member that maintains the coil 3c in a compressed state in which the axial length is shorter than the free length of the coil 3c. Specifically, the configuration includes a pair of end surface support portions 51 that are in contact with both end surfaces 33e of the coil 3c and a connection portion 53 that connects the both end surface support portions 51. The vertical cross-sectional shape (a step surface shape parallel to the axial direction of the coil 3c) is a [type.

  The number and position of the axial length maintaining jig 5 can be selected as appropriate. When one axial length maintaining jig 5 is arranged in combination with an end fixing jig that does not have the function of the axial length maintaining jig 5, the end 3e of the winding 3w is drawn out from the coil 3c ( It is preferable to arrange the axial length maintenance jig 5 on the opposite side (lower surface side) of the upper surface side. In that case, the axial length maintaining jig 5 is not arranged on the upper surface side, but the axial length of the coil 3c on the upper surface side is maintained to some extent by fixing the end portions 3e to each other by the end fixing jig 4. Since the axial length of the coil 3c on the side is maintained by the axial length maintaining jig 5, it becomes easy to maintain the desired axial length along the circumferential direction of the coil 3c. Moreover, you may arrange | position to the installation side of the coil 3c. In either case, an increase in the number of parts can be suppressed. And when arranging two or more, for example, when arrange | positioning even number of axial length maintenance jig | tool 5, it is good to arrange | position in the position which the circumferential direction of the coil 3c opposes. Specifically, they are arranged at least on the side from which the end portion 3e of the winding 3w is drawn (in this example, the opening side of the case 8) and on the opposite side (in this example, the bottom surface side of the case 8). It is done. On the other hand, when an odd number of axial length maintaining jigs 5 are arranged, it is preferable to arrange them so that the shortest distances between adjacent axial length maintaining jigs are approximately equal. By doing so, it is easy to maintain the axial length at a desired length over the entire circumference of the coil 3c. In this example, axial length maintaining jigs 5u and 5d are arranged on the side (end side) from which the end 3e of the winding 3w is pulled out and on the side facing the end side (bottom side of the case 8), respectively. To do.

  In this example, as described above, the axial length maintaining jig 5u disposed on the end 3e side of the winding 3w is an integrally formed jig formed integrally with the end fixing jig 4, and is disposed on the bottom side. The axial length maintaining jig 5d is a separate member from the end fixing jig 4.

  First, the axial length maintaining jig 5u on the end 3e side of the winding 3w will be described with reference to the upper part of FIG. The axial length maintaining jig 5u includes a pair of end surface support portions 51u and a connection portion 53u that connects the both end surface support portions 51u.

  The end surface support portion 51u is a member that supports the coil 3c from its axial direction by contacting both end surfaces 33e of the coil 3c. When the end surface shape of the coil 3c is a race track as in this example, the end surface of the coil 3c may be brought into contact with the semicircular arc portion 31 or may be brought into contact with the straight portion 32. Here, it is in contact with the straight portion 32.

  Examples of the shape of the end surface support portion 51u include various shapes such as a rectangle, a semicircle, and a polygon. Among these, a shape that matches the shape of the end surface 33e of the coil 3c is preferable. Specifically, when the end surface support portion 51u contacts the semicircular arc portion 31 on the end surface 33e of the coil 3c, the shape of the end surface support portion 51u may be a curved flat plate along the semicircular arc portion 31. Moreover, when the end surface support part 51u contact | abuts to the linear part 32 in the end surface 33e of the coil 3c, making the shape of the end surface support part 51u into a rectangular flat plate along the linear part 32 is mentioned. By doing so, it is easy to support the coil 3c from the axial direction. In particular, the inner peripheral surface of the coil 3 c in the end surface support portion 51 u is preferably shaped along the outer peripheral surface of the inner core portion 71. In that case, when it arrange | positions at the installation surface side of the coil 3c like the axial length maintenance jig | tool 5d mentioned later, the inner core part 71 can be supported stably. In this example, it is a rectangular flat plate.

  The height of the end surface support portion 51u (the length from the inner peripheral surface side to the outer peripheral surface side of the coil 3c) may be equal to the width of the coil 3c as long as the end surface of the coil 3c can be supported, or from the width of the coil 3c. May be small or large. When the width of the coil 3c is larger than that of the coil 3c, at least the clearance between the coil 3c and the inner core portion 71 can be ensured by the amount protruding to the inner peripheral surface side of the coil 3c, and insulation between the coil 3c and the inner core portion 71 can be ensured. It becomes easy. Here, it is made smaller than the width of the coil 3c.

  The end face support 51u is preferably provided with a groove 52 for facilitating the distribution of the constituent material of the shape holding member 6 over the entire area of the coil 3c when the coil molded body 3 is molded. The groove 52 is preferably provided, for example, on the outer peripheral surface side of the coil 3c in the end face support 51u over at least a part of the end face support 51u in the width direction, in particular, over the entire length in the width direction. If it does so, it will become easy to distribute the constituent material of the shape holding member 6 to the whole region of the coil 3c, supporting the coil 3c by the end surface support part 51u.

  The connecting portion 53u is a member for connecting the pair of end surface support portions 51u. The connecting portion 53u may be arranged along the axial direction on the outer peripheral surface of the coil 3c in order to connect the both-end support portions 51u, or may be arranged along the axial direction on the inner peripheral surface of the coil 3c. Also good. In the former case, it is easy to install the axial length maintaining jig 5u on the coil 3c even if it is integrated with the end fixing jig 4. In the latter case, it is easy to ensure the clearance between the coil 3c and the inner core portion 71. Here, the outer peripheral surface formed by the linear portion 32 of the coil 3c is arranged along the axial direction.

  Examples of the shape of the connecting portion 53u include various shapes such as a rectangular flat plate, a bar having a rectangular or circular cross section, or a combination of these. In this example, the shape of the connecting portion 53u is a substantially Z-shaped flat plate.

  In the case where the coil 3c is disposed on either the outer peripheral surface or the inner peripheral surface, the shape of the surface on the coil 3c side (hereinafter referred to as the inner peripheral surface) of the connecting portion 53u is the shape along the outer peripheral surface or the inner peripheral surface of the coil 3c. And so on. For example, when the outer peripheral surface (inner peripheral surface) formed by the linear portion 32 of the coil 3c is arranged along the axial direction, the inner peripheral surface of the connecting portion 53 may be a flat surface. On the other hand, when the outer peripheral surface (inner peripheral surface) formed by the semicircular arc portion 31 of the coil 3 c is arranged along the axial direction, the inner peripheral surface of the connecting portion 53 is a curved surface along the semicircular arc portion 31. Is mentioned. Here, the inner peripheral surface of the connecting portion 53u is a flat surface. That is, it is parallel to the outer peripheral surface formed by the linear portion 32 of the coil 3c.

  In this example, the connecting portion 53u also serves as the connecting portion of the end fixing jig 4, but the end fixing jig 4 and the axial length maintaining jig 5u may be separate members. In that case, a connection part may be arrange | positioned along the internal peripheral surface of the coil 3c. The clearance between the coil 3c and the inner core portion 71 can be secured by the thickness of the connecting portion, and the insulation between the coil 3c and the inner core portion 71 can be easily secured.

  The connecting portion 53u is preferably provided with a through hole 54. In particular, even when the installation area of the connecting portion 53u with the coil 3c is large, when the through hole 54 is provided, the axial length maintaining jig 5 is provided when the coil 3c is covered with the shape holding member 6 described later. The shape holding member 6 can be easily spread over the surface of the coil 3c through the through hole 54 even at the place. Therefore, it is preferable that the size of the through hole 54 is as large as possible so that the strength of the connecting portion 53u can be ensured. The shape of the through hole 54 is not particularly limited, and examples thereof include various shapes such as a circle, an ellipse, a track shape, and a polygonal shape. In this example, two track-shaped through holes 54 are formed vertically in the axial direction of the coil 3c.

  Next, the axial length maintaining jig 5d disposed on the bottom surface side of the case 8 will be described with reference to the lower part of FIG. The basic configuration of the axial length maintaining jig 5d can be the same as the axial length maintaining jig 5u on the end 3e side of the winding 3w described above. In this example, the configuration is basically the same except that it is an integrally formed jig integrally formed with the end fixing jig 4. Specifically, a connecting portion 53 that connects the pair of end surface maintaining portions 51d and the both end surface supporting portions 51d is provided. Hereinafter, mainly different points will be described.

  In this example, the end surface support portion 51 d of the axial length maintaining jig 5 d abuts on the linear portion 32 on the end surface 33 e of the coil 3 c on the bottom surface side of the case 8. And the connection part 53d is arrange | positioned along the axial direction the outer peripheral surface which the linear part 32 of 3c of a coil forms.

  The height of the end surface support portion 51d on the installation side is larger than the width of the coil 3c, that is, the end surface support portion 51d protrudes to the inside of the coil 3c from the inner peripheral surface of the coil 3c. It is preferable to adjust so that the axis is coaxial with the central axis of the coil 3c. If it does so, the inner core part 71 mentioned later can be installed in the inner peripheral surface side of the coil 3c in the end surface support part 51d. Thereby, the clearance between the coil 3c and the inner core portion 71 can be secured, and the insulation between the coil 3c and the inner core portion 71 can be secured. And the groove part 52 similar to the end surface support part 51u mentioned above is provided also in the bottom face side of this end surface support part 51d over the full length of the width direction.

  The shape of the connecting portion 53d is a rectangular flat plate. The connecting portion 53d is provided with the same number of through holes 54 at the same position as the connecting portion 53u described above.

  Examples of the constituent material of the shaft length maintaining jig 5 include the same materials as those of the end fixing jig 4 described above. The constituent material of the axial length maintaining jig 5 may be made of the same material as the end fixing jig 4 or may be made of another material.

  In the case where a plurality of axial length maintaining jigs 5 are arranged as in this example, they may have the same configuration such as the shape and material, or may have different configurations.

<Shape retention member>
The shape holding member 6 is a member for holding the shape of the coil 3c. Here, as shown in FIG. 2, the axial length maintaining jigs 5u and 5d, the coil 3c, which will be described later, except for the end 3e side of the winding 3w of the end fixing member 4 and the end 3e of the winding 3w. Covers substantially the entire inner core 71. Thereby, the coil 3c maintained by the axial length maintenance jig | tool 5 in the state compressed rather than free length is hold | maintained in the state.

  The covering region of the coil 3c in the shape holding member 6 can be selected as appropriate, and a part of the coil 3c is not covered by the shape holding member 6 and can be exposed. On the other hand, the coil 3c and the inner core are formed by covering substantially the entire surface of the coil 3c including the end fixing jig 4 and the axial length maintaining jig 5 as in this example. The insulating material that is the constituent material of the shape maintaining member 6 can reliably exist between the portion 71, between the coil 3 c and the outer core portion 72, and between the coil 3 c and the case 8. The shape holding member 6 has a substantially uniform thickness. The thickness of the shape holding member 6 can be appropriately selected so as to satisfy desired insulating properties, and examples thereof include about 1 mm to 10 mm.

  The constituent material of the shape holding member 6 has heat resistance that does not soften against the maximum temperature of the coil 3c and the magnetic core 7 when a reactor including the coil molded body 3 is used. An insulating material that can be molded is preferably used. For example, a thermosetting resin such as epoxy, or a thermoplastic resin such as PPS resin or LCP can be suitably used. Here, an epoxy resin is used. Further, when a resin in which a filler made of at least one ceramic selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide is used as a constituent material of the shape holding member 6, the heat of the coil 3c is used. Can be released, and a reactor excellent in heat dissipation can be obtained.

(Inner core part)
The inner core portion 71 is a columnar body having an outer shape along the inner peripheral shape of the coil 3c. Here, as shown in FIG. 2, it is a racetrack-like columnar body. The whole is a solid body made of a compacted body, with no gap material or air gap interposed. And here, as above-mentioned, it is hold | maintained integrally at the coil molded object 3 by the shape holding member 6.

  The green compact includes a coated soft magnetic powder comprising a plurality of coated soft magnetic particles in which soft magnetic particles are coated with an insulating coating. Typically, after forming a coated soft magnetic powder having an insulating coating made of a silicone resin or the like on the surface, or a mixed powder in which a binder is appropriately mixed in addition to the coated soft magnetic powder, the temperature is lower than the heat resistance temperature of the insulating coating. It is obtained by firing with In the production of a green compact, the material of the coated soft magnetic powder, the mixing ratio of the coated soft magnetic powder and the binder, the amount of various coatings including the insulating coating, etc. are adjusted, and the molding pressure is adjusted. Thus, the saturation magnetic flux density can be changed. For example, by using a coated soft magnetic powder with a high saturation magnetic flux density, increasing the proportion of the soft magnetic material by reducing the amount of binder, or increasing the molding pressure, a compact with a high saturation magnetic flux density A molded body is obtained.

  The soft magnetic particles include iron group metals such as Fe, Co, and Ni, and Fe-based alloys containing Fe as a main component, such as Fe-Si, Fe-Ni, Fe-Al, Fe-Co, Fe-Cr, and Fe-. Examples thereof include particles made of an iron-based material such as Si—Al, rare earth metal particles, and ferrite particles. In particular, the iron-based material is easy to obtain a magnetic core having a saturation magnetic flux density higher than that of ferrite. Examples of the insulating coating formed on the soft magnetic particles include a phosphoric acid compound, a silicon compound, a zirconium compound, an aluminum compound, or a boron compound. Examples of the binder include thermoplastic resins, non-thermoplastic resins, and higher fatty acids. This binder disappears by the above baking, or changes to an insulator such as silica. In the compacted body, an insulator such as an insulating coating exists between the magnetic particles, so that the soft magnetic particles are insulated from each other to reduce eddy current loss, and high-frequency power is applied to the coil. Also, the loss can be reduced. A well-known thing can be utilized for a compacting body.

  Here, the inner core portion 71 is made of a compacted body made of a coated soft magnetic powder having a coating such as an insulating coating, and has a saturation magnetic flux density of 1.6 T or more and a saturation magnetic flux of the outer core portion 72. The density is 1.2 times or more. Further, the relative permeability of the inner core portion 71 is 100 to 500, and the apparent relative permeability of the magnetic core 7 composed of the inner core portion 71 and the outer core portion 72 is 10 to 100. When obtaining a constant magnetic flux, the higher the absolute value of the saturation magnetic flux density of the inner core part, and the smaller the saturation magnetic flux density of the inner core part relative to the outer core part, the smaller the cross-sectional area of the inner core part. it can. Therefore, the form with a high saturation magnetic flux density of the inner core part can contribute to the miniaturization of the reactor. The saturation magnetic flux density of the inner core portion 71 is preferably 1.8 T or more, more preferably 2 T or more, and preferably 1.5 times or more, more preferably 1.8 times or more of the saturation magnetic flux density of the outer core portion 72, both of which have an upper limit. Absent. If a laminated body of electromagnetic steel sheets typified by silicon steel sheets is used instead of the green compact, the saturation magnetic flux density of the inner core portion can be further increased.

  In the example shown in FIG. 1, the axial length of the coil 3c in the inner core portion 71 (hereinafter simply referred to as the axial length) is longer than the axial length of the coil 3c when compressed, The vicinity protrudes from the end surface of the coil 3c. The protruding length of the inner core portion 71 can be selected as appropriate. Here, the protrusion length which protrudes from each end surface of the inner core part 71 is equal, and it is set as the grade which the inner core part 71 is supported by the end surface support part 51d of the axial length maintenance jig | tool 5d. In this example, in the inner core portion 71, the protruding lengths protruding from the end faces of the coil 3c are made equal, but they may be different. Moreover, you may arrange | position an inner core part so that a protrusion part exists only from either one end surface of the coil 3c. In that case, on one end surface side of the coil 3c, as described above, one end of the inner core portion 71 is supported by the end surface of the end surface support portion 51d, and on the other end surface side of the coil 3c, the other end portion of the inner core portion 71 is supported. What is necessary is just to bend | fold the front-end | tip part of the other end surface support part 51d to the inner side of the coil 3c so that it can support. That is, the portion housed in the coil 3 c in the end surface support portion 51 d is in a state of being sandwiched between the coil 3 c and the inner core portion 71. Further, the axial length of the inner core portion and the axial length of the coil may be equal, and the axial length of the inner core portion may be shorter than the axial length of the coil. In this case as well, the tip portions of both end surface support portions 51d may be bent in an L shape toward the inner side of the coil 3c.

  Since the reactor 1 of the present invention has a horizontal arrangement as described above, when the reactor 1 is fixed to an installation target, the inner core portion 71 is also arranged in a horizontally long manner in accordance with the arrangement form of the coil 3c (coil molded body 3). Is done.

[Outer core]
The outer core portion 72 covers at least a part of the outer periphery of the reactor component 2 and is connected to the inner core portion 71 to form a closed magnetic circuit. At that time, the outer core portion 72 is provided so that a closed magnetic path is formed when the coil 3c is excited in any of the above-described forms of the relationship between the axial length of the inner core portion 71 and the axial length of the coil 3c. Good. Here, as shown in FIG. 1, the outer peripheral surface of the reactor component 2 is formed so as to cover substantially all of the portions not in contact with the case 8. Thereby, a part of the outer core part 72 is provided so as to connect both end faces of the inner core part 71, so that the magnetic core 7 forms a closed magnetic path.

  The entire outer core portion 72 is formed of a mixture (molded and cured body) containing magnetic powder and resin, and the inner core portion 71 and the outer core portion 72 are formed of the outer core portion 72 without an adhesive. Bonded by constituent resin. Further, the outer core portion 72 is also free of gap material or air gap. Therefore, the magnetic core 7 is an integrated product that is integrated without any gap material.

  Further, the outer core portion 72 covers substantially all of the portions of the coil molded body 3 that are not in contact with the case 8 and seals the coil molded body 3 and the inner core portion 71 to the case 8. Also, it functions as a sealing material for the coil molded body 3 and the inner core portion 71. Therefore, the reactor 1 can protect the coil molded body 3 and the inner core portion 71 from the external environment by the outer core portion 72 and can enhance mechanical protection.

  The outer core portion 72 only needs to be able to form a closed magnetic path, and the shape (covering region of the reactor component 2) is not particularly limited. For example, a form in which a part of the outer periphery of the reactor component 2 is not covered by the outer core portion is allowed. For example, the opening side region of the case 8 is exposed without being covered by the outer core portion on the outer peripheral surface of the reactor component 2, or the bottom side region of the case 8 is a block body, and a groove is formed in the block body. In addition to the linear portion 32 of the coil 3c, a wider region of the semicircular arc portion 31 (for example, a ¼ arc region disposed on the bottom surface side of the case 8) contacts the case 8 (inner bottom surface and side wall). The contact portion can be configured not to be covered by the outer core portion. In addition, a configuration in which a positioning member for the coil 3c is separately disposed on the bottom surface of the case 8 and the contact portion of the coil 3c with the positioning member is not covered by the outer core portion, etc. If the positioning member is made of a material having excellent heat dissipation, the heat dissipation from the coil 3c can be enhanced.

  The molded cured body can typically be formed by injection molding or cast molding. In injection molding, a powder made of a magnetic material and a fluid resin are usually mixed, and the mixed fluid is poured into a molding die (here, case 8) under a predetermined pressure, and then molded. Is cured. In cast molding, a mixed fluid similar to that of injection molding is obtained, and then the mixed fluid is injected into a molding die without applying pressure to be molded and cured.

  In any of the molding methods, the magnetic powder similar to the soft magnetic particles used for the inner core portion 71 described above can be used. In particular, as the soft magnetic particles used for the outer core portion 72, those made of an iron-based material such as pure iron particles or Fe-based alloy particles can be suitably used. Coated soft magnetic particles having a coating made of phosphate or the like on the surface of particles made of a soft magnetic material may be used. As the magnetic particles, particles having an average particle diameter of 1 μm or more and 1000 μm or less, and more preferably 10 μm or more and 500 μm or less are easily used.

  In any of the above-described molding methods, a thermosetting resin such as an epoxy resin, a phenol resin, or a silicone resin can be suitably used as the binder resin. When a thermosetting resin is used, the molded body is heated to thermally cure the resin. A normal temperature curable resin or a low temperature curable resin may be used as the binder resin. In this case, the molded body is allowed to stand at a normal temperature to a relatively low temperature to be cured. Since the molded hardened body has a relatively large amount of resin that is a non-magnetic material, even when the same coated soft magnetic powder as that of the green compact forming the inner core portion 71 is used, the saturation magnetic flux is higher than that of the green compact. It is easy to form a core having a low density and a low magnetic permeability.

  In addition to the magnetic powder and the resin serving as the binder, a filler made of ceramics such as alumina or silica may be mixed into the constituent material of the molded cured body. By mixing the filler having a specific gravity smaller than that of the magnetic powder, uneven distribution of the magnetic powder is suppressed, and an outer core portion in which the magnetic powder is uniformly dispersed can be easily obtained. Moreover, when the said filler is comprised from the material excellent in thermal conductivity, it can contribute to the improvement of heat dissipation. When mixing the said filler, 20 volume%-70 volume% are mentioned, for the total content of magnetic powder and a filler, when an outer core part is 100 volume%.

  When the reactor part 2 is housed in the case 8 in a horizontal arrangement like the reactor 1 and in a state where the reactor part 2 is close to the inner bottom surface of the case 8, the magnetic powder is on the bottom surface of the case 8 during the curing of the molded cured body. It may settle to the side and become an outer core part in which magnetic powder is unevenly distributed on the bottom side. However, even in this case, the inner core portion 71 is also closer to the bottom surface side of the case 8, and the region where the magnetic powder is high in the outer core portion is likely to be in contact with the inner core portion 71. Can be sufficiently formed.

  Here, the outer core portion 72 is composed of a molded and hardened body of a coated soft magnetic powder and an epoxy resin having the above coating on the surface of particles made of an iron-based material having an average particle diameter of 100 μm or less, and a relative magnetic permeability: 5 ˜30, saturation magnetic flux density: 0.5 T or more and less than the saturation magnetic flux density of the inner core portion 71. By making the magnetic permeability of the outer core portion 72 lower than that of the inner core portion 71, the leakage magnetic flux of the magnetic core 7 can be reduced, and the magnetic core 7 having a gapless structure can be obtained. The permeability and saturation magnetic flux density of the molded cured body can be adjusted by changing the blending of the magnetic powder and the resin serving as the binder. For example, when the blending amount of the magnetic powder is reduced, a molded and hardened body having a low magnetic permeability can be obtained.

  In this example, the constituent material of the inner core portion 71 and the constituent material of the outer core portion 72 are different, and the magnetic core 7 is partially different in magnetic characteristics. Specifically, the inner core portion 71 has a higher saturation magnetic flux density than the outer core portion 72, and the outer core portion 72 has a lower magnetic permeability than the inner core portion 71.

[Case]
As shown in FIG. 1, the case 8 is a rectangular parallelepiped box composed of a rectangular bottom surface and four side walls erected from the bottom surface, and the surface facing the bottom surface is open. The case 8 is used as a container for housing an integral part of the reactor component 2 and the magnetic core 7 (outer core portion 72), and is also used as a heat dissipation path. Therefore, the constituent material of the case 8 suitably uses a material having excellent thermal conductivity, preferably a material having higher thermal conductivity than magnetic powder such as iron, for example, a metal such as aluminum, aluminum alloy, magnesium, and magnesium alloy. be able to. Since these aluminum, magnesium, and alloys thereof are lightweight, they are also suitable as materials for automobile parts that are desired to be reduced in weight. Further, since aluminum, magnesium, and alloys thereof are nonmagnetic materials and conductive materials, leakage magnetic fluxes to the outside of the case 8 can be effectively prevented. Here, the case 8 is made of an aluminum alloy.

  In addition, in the example shown in FIG. 1, the case 8 includes an attachment portion 81 having a bolt hole 82 for fixing the reactor 1 to an installation target with a fixing member such as a bolt. By having the attachment portion 81, the reactor 1 can be easily fixed to the installation target by a fixing member such as a bolt. As described above, the three-dimensional case 8 including the mounting portion 81 can be easily manufactured by casting, cutting, or the like.

  Note that the case 8 can be used even when it is opened. However, if the case 8 is provided with a lid made of a conductive material such as aluminum, the leakage flux can be prevented and the outer core portion 72 can be protected from the environment. And mechanical protection. The lid is provided with a notch or a through-hole so that the end 3e of the winding 3w constituting the coil 3c can be pulled out.

<Application>
For example, the reactor 1 has an energization condition of, for example, a maximum current (direct current): about 100 A to 1000 A, an average voltage: about 100 V to about 1000 V, a use frequency: about 5 kHz to about 100 kHz, typically an electric vehicle, a hybrid vehicle, or the like. It can utilize suitably for the component of the vehicle-mounted power converter device.

《Reactor manufacturing method》
The reactor 1 mentioned above can be manufactured as follows, for example.

[Manufacture of reactor components]
First, the reactor component 2 is manufactured. The reactor component 2 including the inner core portion 71 described above can be manufactured using, for example, a pair of openable and closable molds. First, after the inner core portion 71 is disposed in the coil 3c on which the end portion fixing jig 4 and the axial length maintaining jig 5 are mounted, the inner core portion 71 is disposed in the mold. In this state, resin is poured into the mold and then solidified.

[Formation of outer core]
Next, the reactor component 2 in which the coil molded body 3 and the inner core portion 71 are integrated is accommodated in the case 8. Thereafter, a mixed fluid of a magnetic material and a resin constituting the outer core portion 72 is poured into the case 8 to be molded and cured.

(Other)
In addition, in the coil 3c, an insulating paper, an insulating sheet, an insulating tape, an insulating tube (in the vicinity of the end of the winding 3w) that is not covered with the shape holding member 6 and may be in contact with the outer core portion 72 For example, an insulating material such as a heat-shrinkable tube is preferably disposed as appropriate. If it does so, the insulation of the coil 3c and the outer core part 72 can be improved.

"effect"
According to embodiment mentioned above, there exist the following effects.

  (1) By providing the end fixing member 4 and the axial length maintaining jig 5, the coil 3c can be maintained in a state compressed more than the free length, and the end 3e of the coil 3c can be fixed at a desired position. Can be positioned. Therefore, it becomes easy to handle the coil 3c, and the shape holding member 6 is easily covered on the outer periphery of the coil 3c. Therefore, the assembly workability of the reactor is improved.

  (2) Since the inner core portion 71 includes the reactor part 2 integrated with the coil molded body 3 by the shape holding member 6 of the coil molded body 3, the reactor 1 can be easily assembled.

  (3) Since the end fixing jig 4 and the axial length maintaining jig 5 are integrally formed, the axial length of the coil 3c can be maintained at a desired length with one jig. Since the position of the end 3e of the coil 3c can be positioned, an increase in the number of parts can be suppressed.

  (4) Since the axial length maintaining jig 5 is disposed on the end 3e side (the opening side of the case 8) of the coil 3c and the installation side (the bottom surface side of the case 8) of the opposing coil 3c, the coil 3c The desired axial length can be maintained over the entire circumference.

  (5) The reactor 1 has a single coil 3c, and the coil 3c has a horizontal arrangement in which the coil 3c is housed in the case 8 so that the axial direction of the coil 3c is parallel to the bottom surface of the case 8. Is small and small. In particular, the reactor 1 can be formed by edgewise winding using a covered rectangular wire as a winding by making the end surface shape of the coil 3c into a racetrack shape, and the coil 3c can be made small with a high space factor. . Also from this point, the reactor 1 is small. Furthermore, the reactor 1 can use the case 8 as a heat dissipation path, and also protects the integrated part of the reactor component 2 and the magnetic core 7 (outer core portion 72) from the external environment such as dust and corrosion. Or can be mechanically protected.

  (6) Since the outer core portion 72 is made of a mixture of magnetic powder and resin, the outer core portion 72 can be easily formed even when the outer core portion 72 has a complicated shape such as covering a part of the outer peripheral surface of the coil 3c. Excellent productivity. In addition, by using the above mixture, the magnetic characteristics of the outer core portion 72 can be easily changed. The outer core portion 72 includes a resin component, so that even if the case 8 is open, the coil 3c or There is an effect that protection and mechanical protection can be achieved from the external environment in the inner core portion 71.

  (7) By forming the inner core portion 71 as a green compact, a complicated three-dimensional inner core portion 71 such as a columnar body having a racetrack-like outer shape along the inner peripheral shape of the coil 3c is easily formed. And excellent productivity. And the magnetic characteristics, such as a saturation magnetic flux density, can be easily adjusted by making the inner core part 71 into a compacting body.

  (8) When the saturation magnetic flux density of the inner core portion 71 is higher than that of the outer core portion 72, the inner core portion 71 is made of a single material, and when the entire saturation magnetic flux density obtains the same magnetic flux as a uniform magnetic core, The cross-sectional area (surface through which the magnetic flux passes) of the core portion 71 can be reduced, and the size is small in this respect. Further, the reactor 1 has a high saturation magnetic flux density of the inner core portion 71 where the coil 3c is disposed and a low permeability of the outer core portion 72 covering a part of the outer peripheral surface of the coil 3c, so that the gap can be omitted. From this point, it is small. Furthermore, since the reactor 1 does not have a gap for adjusting the inductance over the entire magnetic core 7, the leakage magnetic flux at this gap portion does not affect the coil 3 c, and thus the inner core portion 71. Can be disposed close to the inner peripheral surface of the coil 3c. Therefore, the clearance gap between the outer peripheral surface of the inner core part 71 and the inner peripheral surface of the coil 3c can be made small, and the reactor 1 is small also from this point. In particular, in the reactor 1, the gap can be further reduced by making the outer shape of the inner core portion 71 similar to the inner peripheral shape of the coil 3 c as described above.

  (9) In addition, the reactor 1 forms the magnetic core 7 by joining the inner core portion 71 and the outer core portion 72 with the constituent resin of the outer core portion 72 simultaneously with the formation of the outer core portion 72, and as a result, the reactor Since 1 can be manufactured, there are few manufacturing processes and it is excellent in productivity. Furthermore, since the reactor 1 has a gapless structure, a gap material joining step is not necessary, and the productivity is also excellent in this respect.

<< Embodiment 2 >>
In the first embodiment, the case where the end face shape of the coil is a racetrack shape has been described. In addition, as shown in FIG. 4, the end face shape of the coil 3c can be circular.

  This coil 3c is a cylindrical body formed by spirally winding a winding 3w having the same material and shape as in the first embodiment. Here, the winding 3w is wound so that the end face shape of the coil 3c is circular.

  An end fixing jig 4 for fixing the end 3e of the coil 3c and an axial length maintaining jig 5 for maintaining the coil 3c in a compressed state rather than a free length are provided. And each jig | tool and resin (shape holding member 6) shaping | molding procedure can be set as the structure similar to Embodiment 1 mentioned above. Here, in the axial length maintaining jig 5d, the inner peripheral surface of the connecting portion 53d is formed of a curved flat plate along the outer peripheral surface of the coil. Moreover, the inner peripheral side of the coil 3c in the end surface support portion 51d is curved along the circular inner core portion 71 along the inner peripheral shape of the coil 3c.

  According to this form, even if the end surface shape of the coil 3c is a circle, the axial length of the coil 3c can be maintained at a desired length, and the end of the coil 3c can be positioned at a desired position. Moreover, the inner core part can be stably supported because the inner peripheral side of the coil 3c in the end surface support part 51d of the axial length maintaining jig 5d on the installation side is curved along the outer shape of the inner core part. In addition, since the inner peripheral surface of the connecting portion 53d is curved along the outer peripheral surface of the coil 3c, the coil 3c can be stably supported.

<< Embodiment 3 >>
In the first and second embodiments, the configuration including the reactor component 2 in which the inner core portion 71 and the coil molded body 3 are integrated by the shape holding member 6 of the coil molded body 3 has been described. In addition, as shown in FIG. 5, the inner core portion and the coil molded body 3 may not be integrated by the shape holding member 6.

  The coil molded body 3 has a hollow hole that covers the inner peripheral surface of the coil 3 c and is formed of a constituent material (insulating resin) of the shape maintaining member 6. The inner core portion is inserted into the hollow hole. By adjusting the thickness of the constituent material of the shape holding member 6 so that the inner core portion is disposed at an appropriate position on the inner periphery of the coil 3c, and adjusting the shape of the hollow hole to the outer shape of the inner core portion, The constituent material can function as a positioning portion for the inner core portion.

  Such a coil molded body 3 can be manufactured by arranging a core having a predetermined shape instead of the inner core portion 71 in the manufacturing process of the reactor component 2 described in the first embodiment. Moreover, the reactor which provides such a coil molded object 3 inserts and arranges an inner core part in the hollow hole of the obtained coil molded object 3, and uses the assembly of this coil molded object 3 and an inner coil part as a case. It can be manufactured by housing and forming the outer core part. That is, a reactor in which a combination of a magnetic core having an inner core portion and an outer core portion and the coil molded body 3 is housed in a case is obtained.

  Similarly to the reactor component 2 of the first embodiment, this configuration also makes it easy to handle the coil 3c because the shape holding member 6 holds the shape of the coil 3c together with the end fixing jig 4 and the axial length maintaining jig 5. . Also, in this embodiment, similarly to the reactor component 2 of the first embodiment, the shape holding member 6 is provided between the coil 3c and the inner core portion, between the coil 3c and the outer core portion, and between the coil 3c and the case. By interposing, the insulation between the coil 3c and the magnetic core and the insulation between the coil 3c and the case can be enhanced.

<< Embodiment 4 >>
In the first embodiment, the case where the end face shape of the coil is a racetrack is described, and in the second embodiment, the case where the end face shape of the coil is a circle is described. Is replaced with a straight line parallel to the major axis, and a different shape having one straight part, a rounded rectangular shape can be obtained.

  The elliptical coil is a horizontally long elliptical shape having a large aspect ratio (major axis / minor axis), and when the major axis is arranged in parallel with the bottom surface of the case, the inner coil of the case (by extension, the object to be installed) in the coil. Heat dissipation can be improved by increasing the number of adjacent areas. Moreover, this horizontally long coil is small in volume and small. A coil composed of only such a curve can be easily formed by using, for example, a round wire having a circular cross section of the conductor. Furthermore, if the area of the inner circumference of the elliptical coil is constant, the circumference can be shortened compared to the reactor 1 of the first embodiment, so that the amount of winding used is reduced, loss such as copper loss is reduced, Weight reduction can be achieved.

  Since the irregularly shaped coil and the rounded rectangular coil have a straight line portion like the coil 3c of the reactor 1 of the first embodiment, even when the inner bottom surface of the case is a flat surface, contact with the inner bottom surface is possible. In addition to ensuring a sufficient area, the case has excellent stability. An irregularly shaped coil can be easily formed by using the round wire. On the other hand, the rounded rectangular coil can be an edgewise coil using a rectangular wire, like the coil 3c of the reactor 1 of the first embodiment, and the space factor can be increased. Can do.

  In addition, this invention is not limited to the above-mentioned embodiment, The above-mentioned embodiment can be changed suitably, without deviating from the summary of this invention.

  The reactor of the present invention can be used for components of a power conversion device such as a DC-DC converter mounted on a vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle. The coil molded body of the present invention and the reactor component of the present invention can be suitably used for a reactor.

DESCRIPTION OF SYMBOLS 1 Reactor 2 Reactor part 3 Coil molded object 3c Coil 3w Winding 3e End part 31 Semicircular arc part 32 Straight line part 33e End surface 4 End part fixing jig 40 Gripping part 5, 5u, 5d Axis length maintenance jig 51, 51u, 51d End surface support portion 52 Groove portion 53, 53u, 53d Connection portion 54 Through hole 6 Shape holding member 7 Magnetic core 71 Inner core portion 72 Outer core portion 8 Case 81 Mounting portion 82 Bolt hole

Claims (8)

A coil molded body used for a reactor including a coil formed by winding a winding spirally,
An end fixing jig that fixes both ends of the coil and positions each other;
An axial length maintaining jig for maintaining the coil in a compressed state shorter than the free length of the coil;
A shape holding member made of an insulating material, covering at least a part of the surface of the coil and holding the shape of the coil,
The coil molded body, wherein the end fixing jig and the axial length maintaining jig are integrally fixed to the coil by the shape holding member.   The coil molded body according to claim 1, wherein the end fixing jig and the shaft length maintaining jig are integrally formed jigs.   The coil molded body according to claim 1 or 2, wherein the end fixing jig and the shaft length maintaining jig are separate members. The axial length maintenance jig is
End surface support portions in contact with both end surfaces of the coil;
A connecting portion for connecting the both end surface support portions;
The coil molded body according to any one of claims 1 to 3, wherein the connecting portion is provided with a through hole and filled with a constituent material of the shape maintaining member. The coil molded body according to any one of claims 1 to 4,
An inner core portion disposed in the coil of the coil molded body,
The reactor core part, wherein the inner core part is integrally held by a shape holding member of the coil molded body.   The said inner core part is a compacting body formed by press-molding a coated soft magnetic powder comprising a plurality of coated soft magnetic particles in which a soft magnetic particle is coated with an insulating coating. Reactor parts as described in 1. The coil molded body according to any one of claims 1 to 4,
An inner core portion disposed in the coil of the coil molded body;
An outer core part that is composed of a mixture containing magnetic powder and resin, covers at least a part of the outer periphery of the coil molded body, and is connected to the inner core part to form a closed magnetic path;
A reactor comprising: a magnetic core having the inner core portion and the outer core portion; and a case that houses a combination of the coil molded body. The reactor component according to claim 5 or 6,
An outer core part that is composed of a mixture containing magnetic powder and resin, covers at least a part of the outer periphery of the reactor part, and is connected to the inner core part of the reactor part to form a closed magnetic path;
A reactor comprising a case for housing an integral part of the reactor component and the outer core portion.

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