JP2016092201A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor capable of easily positioning a plurality of core pieces and gap materials for constructing a magnetic core, and has excellent assembly workability.SOLUTION: A reactor comprises: an insulation inclusion member 5 interposed between a coil 2 having a pair of wound parts 2a and 2b in a lateral array and a magnetic core 3 having a part arranged in the wound part. The magnetic core 3 includes: a plurality of inner core pieces 31m arranged in the wound part; a pair of U-shaped outer core pieces 32m in which a side base part 321 and a pair of middle part 322 are integrally formed; and an edge part gap material 31g interposed between the inner core piece 31m and the outer core piece 32m. The insulation inclusion member 5 includes: a first end surface inclusion part 52a and a second end surface inclusion part 52b interposed between an end surface in an axial direction of the wound parts 2a and 2b and the outer core piece 32m; and a pair of inner side inclusion part 51 that is interposed among the inner surface of wound parts 2a and 2b, the inner core piece 31m, and the middle part 322, and houses a whole of the inner core piece 31m and the edge part gap material 31g.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a reactor that is used in a vehicle-mounted DC-DC converter or a component of a power converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor that can easily position a plurality of core pieces and gap members constituting a magnetic core and has excellent assembly workability.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. Patent Document 1 discloses a coil having a pair of coil elements (winding portions) wound with a winding, an annular magnetic core in which the coil is disposed, and a bobbin interposed between the coil and the magnetic core. A reactor including (intervening member) is disclosed. The interposition member includes a cylindrical bobbin (inner interposition part) that covers the outer periphery of a plurality of inner core pieces (intermediate cores) arranged in the winding part, and a pair of frame-shaped bobbins (end faces) that come into contact with the end face of the winding part Interposition part).

  The reactor disclosed in Patent Document 1 has one end core (an outer core piece not disposed in the winding portion) attached to one end face interposed portion ⇒ an inner interposed portion attached to this end face interposed portion ⇒ Insert the inner core piece inside ⇒ Attach the winding part to the outer periphery of the inner interposition part ⇒ Attach the other end face interposition part to the inner interposition part ⇒ Attach the other outer core piece to the other end face interposition part (See FIG. 5 of Patent Document 1).

JP 2010-263075 A

  Improvement of the assembly workability of the reactor is desired.

  A gap material is interposed between the core pieces. As an arrangement relationship between the core piece and the gap material, for example, the gap material may be arranged on the end surface of the inner core piece. In the interposition member (inner interposition portion) of Patent Document 1, since the core piece at the end projects from the interposition member, the gap material cannot be positioned when the gap material is disposed on the core piece at the end. .

  Moreover, in patent document 1, positioning of the outer core piece with respect to an end surface interposition part is performed by inserting an outer core piece in the convex part formed in the end surface interposition part. However, the contact surface of the outer core piece with the inner core piece is flat, and if the outer core piece is simply fitted into the convex portion formed at the end surface interposition part, the positioning state of both may become unstable.

  The present invention has been made in view of the above circumstances, and one of the objects of the present invention is to provide a reactor that can easily position a plurality of core pieces and gap members constituting a magnetic core and has excellent assembly workability. There is.

  A reactor according to an aspect of the present invention includes a coil having a pair of winding portions wound around a winding, a magnetic core having a portion disposed in the winding portion, the coil, and the magnetic core. And an insulating interposition member interposed between the two. The magnetic core includes a plurality of inner core pieces, a pair of U-shaped outer core pieces, and an end gap material. The inner core piece is disposed in the winding part. The outer core piece includes a side base portion disposed outside the winding portion so as to straddle between the winding portions, and a pair of middle portions that protrude from the side base portion and are respectively disposed in the winding portion. And the side base portion and each of the middle portions are integrally formed. The end gap material is interposed between the inner core piece and each of the pair of outer core pieces. The insulating interposition member includes a first end surface interposition portion, a second end surface interposition portion, and a pair of inner interposition portions. The first end surface interposed portion is interposed between one end surface in the axial direction of the winding portion and one of the pair of outer core pieces, and has two insertion holes through which the middle portions can be respectively inserted. The second end surface interposed portion is interposed between the other end surface in the axial direction of the winding portion and the other of the pair of outer core pieces, and has two insertion holes through which the middle portions can be inserted. The inner interposition part is interposed between the inner surface of the winding part and the inner core piece and the middle part, and accommodates all of the inner core piece and the end gap material.

  The reactor can easily position a plurality of core pieces and gap members constituting the magnetic core, and is excellent in assembling workability.

It is a schematic perspective view which shows the reactor of Embodiment 1. FIG. It is a disassembled perspective view which shows the outline of the reactor of Embodiment 1. FIG. It is a perspective view which shows the interposed member with which the reactor of Embodiment 1 is equipped. It is a schematic perspective view for demonstrating the reactor assembly method of Embodiment 1. FIG. It is a perspective view which shows the interposed member with which the reactor of Embodiment 2 is equipped.

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

  (1) A reactor according to an aspect of the present invention includes a coil having a pair of winding portions wound around a winding, a magnetic core having a portion disposed in the winding portion, the coil, and the coil And an insulating interposition member interposed between the magnetic core and the magnetic core. The magnetic core includes a plurality of inner core pieces, a pair of U-shaped outer core pieces, and an end gap material. The inner core piece is disposed in the winding part. The outer core piece includes a side base portion disposed outside the winding portion so as to straddle between the winding portions, and a pair of middle portions that protrude from the side base portion and are respectively disposed in the winding portion. And the side base portion and each of the middle portions are integrally formed. The end gap material is interposed between the inner core piece and each of the pair of outer core pieces. The insulating interposition member includes a first end surface interposition portion, a second end surface interposition portion, and a pair of inner interposition portions. The first end surface interposed portion is interposed between one end surface in the axial direction of the winding portion and one of the pair of outer core pieces, and has two insertion holes through which the middle portions can be respectively inserted. The second end surface interposed portion is interposed between the other end surface in the axial direction of the winding portion and the other of the pair of outer core pieces, and has two insertion holes through which the middle portions can be inserted. The inner interposition part is interposed between the inner surface of the winding part and the inner core piece and the middle part, and accommodates all of the inner core piece and the end gap material.

  According to the above configuration, the outer core piece is formed in a U-shape including the side base portion and the pair of middle portions, so that the outer core piece is disposed on each of the first end surface interposed portion and the second end surface interposed portion of the insulating interposed member. When attaching, a pair of middle part is penetrated by the insertion hole of an end surface interposition part. Therefore, the positioning between the pair of middle portions and the end surface interposed portion can be facilitated, and the positioning state between the pair of middle portions (outer core pieces) and the end surface interposed portion can be ensured stably. Therefore, it is easy to attach the outer core piece to each end face interposition part, and the workability is excellent. Since the inner interposition part can accommodate all of the inner core piece and the end gap material, the inner core piece and the gap material can be positioned with respect to the inner interposition part, and the positioning state is stably secured. be able to. Therefore, even when a gap material thinner than the inner core piece is disposed on the end surface of the inner core piece, the gap material can be prevented from falling off from the inner intervening portion, and the inner core piece and the gap material can be attached to the inner intervening portion. Easy installation and excellent workability. As described above, by assembling the first end face interposed portion, the second end face interposed portion, and the inner interposed portion, the positioning of the plurality of core pieces and the gap material can be facilitated, and the reactor assembly workability is excellent.

  (2) As an example of the reactor, the insulating interposed member is a member in which both the first end surface interposed portion and the inner interposed portion are integrally formed, and the second end surface interposed portion is independent. One form is mentioned.

  According to the above configuration, since the insulating interposition member can be handled as a two-part product in which the integral member and the second end surface interposition member are independent, the assembly workability of the reactor is further improved. In addition, since the pair of inner interposed portions are integrally formed with the first end surface interposed portion, the wobbling of each inner interposed portion with respect to the first end surface interposed portion can be easily suppressed and handled easily.

  (3) As an example of the reactor, at least one of the first end surface interposed portion and the second end surface interposed portion and the inner interposed portion may include an engagement portion that engages with each other.

  According to the said structure, by positioning each interposition part by an engaging part mutually, positioning of a some core piece and gap material can be made easier, and it is further excellent in the assembly workability | operativity of a reactor.

  (4) As an example of the reactor described above, the inner interposed portion is a cylindrical body along the outer shape of the inner core piece, and one end in the axial direction of the cylindrical body is provided at a location opposite to the side surface of the cylindrical body. The form by which the side opened and the slit by which the other end side was obstruct | occluded is formed is mentioned.

  At the time of assembling the core piece, the axial direction of the inner interposition part may be set to the vertical direction, and a plurality of inner core pieces and gap materials may be inserted and arranged in the inner interposition part. At that time, according to the above configuration, each core piece and the side surface of the gap material can be inserted into the inner interposition part from the opening side of the slit, so that a plurality of inner core pieces and gap material can be stored. Easy to do. In addition, the inner core piece and the gap material can be stored in the inner intervention portion while holding the inner core piece and the gap material without dropping the inner core piece and the gap material from one end side of the inner interposed portion. Can be prevented.

[Details of the embodiment of the present invention]
Details of the embodiment of the present invention will be described below. In addition, this invention is not limited to these illustrations, is shown by the claim, and intends that all the changes within the meaning and range equivalent to a claim are included. The same code | symbol in a figure shows the same name thing.

<Embodiment 1>
The reactor 1 of Embodiment 1 is demonstrated with reference to FIGS.

(Reactor)
-Overall structure As shown in FIG. 1, the reactor 1 of Embodiment 1 has the coil 2 which has the winding parts 2a and 2b formed by winding the coil | winding 2w helically, and the winding parts 2a and 2b of the coil 2 The magnetic core 3 which has the part arrange | positioned inside and outside, and the insulation interposition member 5 interposed between the coil 2 and the magnetic core 3 are provided. In the reactor 1, the outer core piece 32m having a portion disposed outside the winding portions 2a and 2b of the magnetic core 3 has a specific shape (see FIG. 2), and the insulating interposed member 5 has a specific shape. One of the features is as follows (see FIGS. 2 to 4). Hereinafter, each component will be described in detail.

The coil 2 includes a pair of cylindrical winding parts 2a and 2b formed by spirally winding a single continuous winding 2w, as shown in FIGS. And a connecting portion 2r for connecting 2a and 2b. Each winding part 2a, 2b is formed in a hollow cylinder shape with the same number of turns and the same winding direction, and is arranged in parallel (side by side) so that the respective axial directions are parallel. The connecting portion 2r is a portion bent in a U shape that connects the winding portions 2a and 2b. The coil 2 may be formed by spirally winding a single winding without a joint. Alternatively, the windings 2a and 2b may be formed by separate windings, and the windings 2a and 2b You may form by joining the edge parts of a coil | winding by welding or crimping | compression-bonding. Both end portions of the coil 2 are extended in appropriate directions from the winding portions 2a and 2b and connected to a terminal member (not shown). An external device such as a power source for supplying power is connected to the coil 2 through the terminal member.

  Each winding part 2a, 2b of this embodiment is formed in the shape of a square tube. The rectangular cylindrical winding parts 2a and 2b are winding parts having rounded corners whose end face shape is a quadrangle (including a square shape). Of course, the winding portions 2a and 2b may be formed in a cylindrical shape. The cylindrical winding portion is a winding portion whose end face shape is a closed curved surface shape (an elliptical shape, a perfect circle shape, a race track shape, etc.).

  The coil 2 including the winding portions 2a and 2b is a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor such as a flat wire or a round wire made of a conductive material such as copper, aluminum, magnesium, or an alloy thereof. Can be configured. In the present embodiment, the winding portions 2a and 2b are formed by edgewise winding a rectangular wire made of copper and a conductor made of enamel (typically polyamideimide). Yes.

-Magnetic core As shown in FIG. 2, the magnetic core 3 includes a plurality of columnar inner core pieces 31m,..., A pair of U-shaped outer core pieces 32m, 32m, and a plurality of intervening core pieces. Gap materials 31g are provided. The outer core pieces 32m and 32m are arranged so that the U-shaped end faces face each other, and a laminate of the inner core piece 31m and the gap material 31g is arranged side by side (in parallel) between the outer core pieces 32m and 32m. With this arrangement, the magnetic core 3 is assembled in an annular shape, and forms a closed magnetic path when the coil 2 is excited. A part of the inner core piece 31m and the outer core piece 32m in the magnetic core 3 constitutes a part arranged in the winding portions 2a and 2b of the coil 2, and the coil 2 is arranged in the remaining part of the outer core piece 32m. First, a portion protruding from the coil 2 is formed.

.. Inner core piece The inner core piece 31m preferably has a shape that matches the shape of the winding portions 2a and 2b. Here, as shown in FIG. 2, the shape of the inner core piece 31m is a rectangular parallelepiped shape, and the corners thereof are rounded along the corners of the inner peripheral surfaces of the winding portions 2a and 2b. The number of inner core pieces 31m can be selected as appropriate.

.. Outer core piece The pair of outer core pieces 32m, 32m have the same shape, and are U-shaped when viewed from above in FIG. The outer core piece 32m is disposed outside the winding portions 2a and 2b and is disposed so as to straddle between the winding portions 2a and 2b, and protrudes from the side base portion 321 and enters the winding portions 2a and 2b. It has a pair of middle parts 322 and 322 arranged respectively. Each of the side base portion 321 and the middle portions 322 and 322 is an integrally formed object. Here, the side base portion 321 is integrally formed with a protruding portion that protrudes on the opposite side to the middle portions 322 and 322.

  The side base portion 321 has a rectangular parallelepiped shape, and a pair of middle portions 322 and 322 protrude in parallel from an inner end surface 32e facing the end surfaces of the winding portions 2a and 2b. Each of the middle portions 322 and 322 is a rectangular parallelepiped portion having an end surface 322e formed of a rectangular plane when viewed from the front, and is separated from the side base portion 321 so as to sandwich a central region in the parallel direction of each middle portion 322. (See FIG. 2). The end surfaces 322e of the middle portions 322 and 322 have substantially the same shape and size as the end surface of the inner core piece 31m (the end surface of the gap member 31g described later). The size and protrusion length of the middle portion 322 can be appropriately selected so as to have a predetermined magnetic path cross-sectional area corresponding to the coil 2. The middle portions 322 and 322 preferably have a shape that matches the shape of the winding portions 2a and 2b. Here, the corner portions are substantially along the corner portions of the inner peripheral surfaces of the winding portions 2a and 2b. It is rounded. Here, the upper surface of the side base portion 321 and the upper surfaces of the pair of middle portions 322 are flush with each other, and the lower surface of the side base portion 321 is formed so as to protrude from the lower surface of the middle portion 322.

  In this example, both the inner core piece 31m and the outer core piece 32m are compacted bodies. The green compact is typically a raw material powder containing a soft magnetic metal powder such as iron or an iron alloy (Fe-Si alloy, Fe-Ni alloy, etc.) and a binder (resin etc.) or a lubricant as appropriate. After being molded, it is obtained by performing a heat treatment for the purpose of removing distortion associated with the molding. By using, as a raw material powder, a coating powder obtained by subjecting a metal powder to insulation treatment, or a mixed powder obtained by mixing a metal powder and an insulating material, the metal powder and the insulating material interposed between the metal particles after forming are substantially used. A compacted green body is obtained. Since this compacting body contains an insulating material, eddy current can be reduced and the loss is low.

.. Gap material The gap material 31g is made of a material having a lower relative permeability than the core pieces 31m and 32m, typically a non-magnetic material such as alumina. In this example, the gap material 31g is a non-magnetic material flat plate having a rectangular shape in plan view. The shape and number of the gap material 31g can be selected as appropriate. The gap material 31g interposed between the inner core pieces 31m can be used as an air gap instead of the gap material 31g or in combination with the gap material 31g. The gap material disposed at the end of the inner core piece 31m, that is, the gap material (end gap material) 31g interposed between the inner core piece 31m and the outer core piece 32m is a flat plate of the above-described nonmagnetic material. is there.

Insulating interposed member The insulating interposed member 5 is interposed between the coil 2 and the magnetic core 3, and has a function of improving the insulation between the coil 2 and the magnetic core 3. As shown in FIG. 2, the insulating interposition member 5 is interposed between the winding portions 2a and 2b and a portion (mainly the inner core piece 31m) of the magnetic core 3 that is disposed in the winding portions 2a and 2b. And a first end surface interposed portion 52a and a second end surface interposed portion 52b interposed between the winding portions 2a and 2b and the outer core pieces 32m and 32m. In this example, as shown in FIGS. 2 and 3, the insulating interposed member 5 includes an integrated member (divided material 50 a) in which the first end surface interposed portion 52 a and the inner interposed portions 51, 51 are integrally formed, and a second member. The end surface interposed member 52b (divided material 50b) is constituted by two independent products.

  As shown in FIGS. 2 and 3, the first end surface interposed portion 52a of the split member 50a has two insertion holes 52h and 52h through which the pair of middle portions 322 and 322 of one outer core piece 32m can be inserted, respectively. It is a frame-shaped part of a B-shaped flat plate. In the first end surface interposed portion 52a, the inner interposed portions 51 and 51 and the partition portion 52d are integrally formed on the surface facing the winding portions 2a and 2b.

  The inner interposition parts 51, 51 accommodate a laminate of the inner core piece 31m and the gap material 31g. Here, each inner intervening portion 51 is composed of four curved plate pieces so as to correspond to each of the four corner portions of the laminate, and each corner portion of the laminate is formed on each plate piece. By being along, it becomes easy to store the laminate in the inner interposition portions 51, 51. Due to the four plate pieces, the inner interposition parts 51, 51 are formed into a cylindrical body along the outer shape of the inner core piece 31m. The number of the plate pieces can be appropriately changed as long as the laminate can be accommodated. Each plate piece protrudes from the coil side surface of the first end face interposition part 52a and is provided in a frame shape in which the pieces are connected on the surface side. Therefore, the inner interposition parts 51 and 51 are formed with slits 51s that are open at one end side in the axial direction of the cylindrical body and closed at the other end side on the side surface of the cylindrical body.

  The split member 50a includes an engaging portion that engages with the other split member 50b. Here, a concave engaging portion 51 e is formed at the tip of each plate piece of the inner interposition portion 51. The engaging portion 51e can be held in a state in which the divided members 50a and 50b are positioned relative to each other by being engaged with a convex engaging portion 52e formed on the divided member 50b described later.

  The partition portion 52d is provided at a position between the inner interposed portions 51 and 51 so as to protrude from the coil side surface of the first end surface interposed portion 52a. This partition part 52d is interposed between the winding parts 2a and 2b when the divided pieces 50a and 50b are assembled to the winding parts 2a and 2b, and maintains the isolated state of the winding parts 2a and 2b (FIG. 2). See). By this isolation, the insulation between the winding parts 2a and 2b can be ensured.

  The other split member 50b is composed of a second end face interposition part 52b, and, as shown in FIG. 3, two insertion holes 52h and 52h through which the pair of middle parts 322 and 322 of the other outer core piece 32m can be inserted respectively. It is a frame-shaped part of the B-shaped flat plate which it has. The second end surface intervening portion 52b is integrally formed with an engaging portion 52e and a partition portion 52d that engage with the engaging portion 51e formed on the split piece 50a on the surface facing the winding portions 2a and 2b. ing. The engaging portion 52e is formed so as to protrude from the surface facing the winding portions 2a and 2b, and this protruding portion (convex portion) is engaged with the concave engaging portion 51e formed in the split piece 50a. Match. The engaging portion 52e is formed to correspond to the engaging portion 51e formed in the split piece 50a, and here, it is composed of four curved plate pieces for each of the insertion holes 52h and 52h. The partition part 52d is formed so as to protrude from the surface facing the winding parts 2a and 2b at a position between the insertion holes 52h and 52h.

  As a constituent material of the insulating interposition member 5, an insulating material such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, or liquid crystal polymer (LCP) can be used. The insulating interposed member 5 can be easily manufactured by a known molding method such as injection molding of the above resin.

(Reactor manufacturing method)
The manufacturing method of the reactor 1 provided with the structure demonstrated above is demonstrated based on FIG. The reactor 1 is manufactured in a state where the inner end face 32e of the outer core piece 32m is in the vertical direction so that the axial direction of the inner core piece 31m is in the vertical direction.

-Attaching one outer core piece to the first end face interposition part First, one outer core piece 32m is attached to the first end face interposition part 52a of the one split piece 50a. Specifically, the split piece 50a is attached to the outer core piece 32m so that the pair of middle portions 322 and 322 of the outer core piece 32m are inserted through the insertion holes 52h and 52h of the first end surface interposed portion 52a (FIG. 4). (See the left figure). At this time, one outer core piece 32m is positioned with respect to the first end surface interposed portion 52a (divided piece 50a). Further, since the pair of middle portions 322 and 322 are inserted through the insertion holes 52h and 52h, the positioning state between the outer core piece 32m and the first end surface interposed portion 52a (divided piece 50a) is stably secured. .

-Attachment of inner core piece and gap material to inner interposition part Next, the laminated body of the some inner core piece 31m and the gap material 31g is inserted inside the inner interposition part 51 among the division | segmentation pieces 50a. Specifically, the gap member 31g and the inner core piece 31m are sequentially inserted and stacked inside the inner interposed portion 51. The inner core piece 31m and the outer core piece 32m are laminated so that the gap material 31g is interposed (see the left figure of FIG. 4). As a result, the end surfaces 322e of the middle portions 322 and 322 of the outer core piece 32m come into contact with the gap material 31g. At this time, all of the plurality of inner core pieces 31m and the gap material 31g are housed inside the inner interposed portion 51, and a laminate of the inner core piece 31 and the gap material 31g with respect to the inner interposed portion 51 (divided piece 50a). Is positioned. Since the end gap material 31g located at the end (the gap material 31g located at the top in the left view of FIG. 4) is also housed inside the inner interposition part 51, it will not fall off from the inner interposition part 51. Absent.

-Attachment of winding part Next, winding part 2a, 2b is mounted | worn to the outer periphery of the inner side interposed part 51 (refer the middle figure of FIG. 4).

-Attachment of the 2nd end surface interposition part to an inner side intervention part Next, the other division | segmentation piece 50b (2nd end surface interposition part 52b) is attached to the inner side interposition part 51. FIG. Specifically, the convex engaging portions 52e formed on the split piece 50b are fitted into the concave engaging portions 51e formed on the split piece 50a, and the split pieces 50a and 50b are engaged (FIG. (See right figure 4 and figure 3).

-Attachment of the other outer core piece to a 2nd end surface interposition part Finally, the other outer core piece 32m is attached to the other division piece 50b (2nd end surface interposition part 52b). Specifically, the outer core piece 32m is attached to the divided piece 50b so that the pair of middle portions 322 and 322 of the outer core piece 32m are inserted through the insertion holes 52h and 52h of the second end surface interposed portion 52b (FIG. 4). (See the right figure). At this time, the other outer core piece 32m is positioned with respect to the second end face interposed portion 52b (divided piece 50b). Further, since the pair of middle portions 322 and 322 are inserted through the insertion holes 52h and 52h, the positioning state between the outer core piece 32m and the second end face interposed portion 52b (divided piece 50b) is stably secured. .

  The reactor 1 obtained by the manufacturing method described above may be stored in a case (not shown). The case typically includes a bottom portion on which the assembly including the coil 2 and the magnetic core 3 is placed, and a side wall portion that stands up from the bottom and surrounds the periphery of the combination, and the side facing the bottom is An open box can be mentioned. Reactor 1 provided with a case can aim at protection from the environment of a combination, and mechanical protection. The reactor 1 provided with a metal case can use the entire case as a heat dissipation path and has excellent heat dissipation, and can well protect the assembly. As the metal constituting the case, it is excellent in thermal conductivity, and lightweight aluminum or aluminum alloy can be suitably used. Other metals include magnesium and magnesium alloys.

  Moreover, it is good also as a structure which filled sealing resin in the case and sealed the reactor 1 with sealing resin. As the sealing resin, for example, an epoxy resin, a urethane resin, a silicone resin, an unsaturated polyester resin, a PPS resin, or the like can be suitably used. From the viewpoint of improving heat dissipation, the sealing resin may be mixed with a ceramic filler having high thermal conductivity such as alumina or silica.

(Main effect)
Since the outer core pieces 32m and 32m are U-shaped including the side base portion 321 and the pair of middle portions 322 and 322, the pair of middle portions 322 and 322 are inserted into the insertion holes 52h and 52h of the end surface interposed portions 52a and 52b. Since it is inserted, it is possible to easily position the outer core pieces 32m and 32m with respect to the end face interposed portions 52a and 52b. In addition, the pair of middle portions 322 and 322 are inserted into the insertion holes 52h and 52h of the end surface interposed portions 52a and 52b, thereby stabilizing the positioning state of the outer core pieces 32m and 32m and the end surface interposed portions 52a and 52b. Can be secured.

  Since the inner interposition part 51 can accommodate all of the inner core piece 31m and the end gap material 31g, the inner core piece 31m and the gap material 31g can be positioned with respect to the inner interposition part 51, and the positioning state thereof Can be secured stably. Therefore, even when the gap material 31g thinner than the inner core piece 31m is disposed on the end face of the inner core piece 31m, the gap material 31g can be prevented from falling off from the inner interposed portion 31, and the inner intermediate portion 51 can be prevented from falling. It is easy to attach the core piece 31m and the gap material 31g and is excellent in workability.

  As described above, by assembling the first end face interposition part 52a, the second end face interposition part 52b, and the inner interposition part 51, the positioning of the plurality of core pieces 31m and the gap material 31g can be facilitated, and the assembly workability of the reactor 1 is improved. Excellent.

  In this example, the insulating interposition member 5 includes an integrated member (divided material 50a) in which the first end surface intervening portion 52a and the inner intervening portions 51, 51 are integrally formed, and a second end surface intervening member 52b (divided material). 50b) is made up of two independent products and is easy to handle. Since the split pieces 50a and 50b are engaged with each other by the engaging portions 51e and 52e, the plurality of core pieces 31m and 32m and the gap material 31g can be reliably positioned.

-Other composition The reactor 1 can be provided with the following members.

.. Heat radiation plate A heat radiation plate (not shown) can be provided at any location on the outer peripheral surface of the coil 2. For example, if a heat sink is provided on the installation surface of the coil 2 (the surface facing the installation target to which the reactor 1 is attached), the heat of the coil 2 is well transmitted to the installation target such as a converter case through the heat dissipation plate to dissipate heat. Increases sex. As the constituent material of the heat sink, a material having excellent thermal conductivity, for example, a metal such as aluminum or an alloy thereof, a non-metal such as alumina, or the like can be used. A heat sink may be provided on the entire installation surface of the reactor 1. The heat sink can be fixed to the coil 2 by, for example, a bonding layer described later.

..Junction Layer Of the installation surface of the reactor 1 (surface facing the installation target to which the reactor 1 is attached), at least the installation surface of the coil 2 can be provided with a bonding layer (not shown). By providing the bonding layer, the coil 2 can be firmly fixed to the heat sink when the installation target or the above-described heat sink is provided, the movement of the coil 2 is restricted, the heat dissipation is improved, the installation target or the heat sink Fixing stability can be achieved. Constituent material of the bonding layer contains an insulating resin, particularly ceramic filler, and has excellent heat dissipation (for example, thermal conductivity is 0.1 W / m · K or more, further 1 W / m · K or more, especially 2 W / M · K or more). Specific examples of the resin include thermosetting resins such as epoxy resin, silicone resin, and unsaturated polyester, and thermoplastic resins such as PPS resin and LCP. When a sheet-like material is used as the bonding layer, the bonding layer is easily arranged.

.. Sensor A sensor (not shown) that measures the physical quantity of the reactor 1 such as a temperature sensor, a current sensor, a voltage sensor, or a magnetic flux sensor can be provided. For example, the sensor can be arranged in a space formed between the two winding portions 2a and 2b.

<Embodiment 2>
In the second embodiment, as shown in FIG. 5, the insulating interposition member 5 is composed of a four-part product in which the first end surface interposition portion 52 a, the second end surface interposition portion 52 b, and the pair of inner interposition portions 51, 51 are independent from each other. The form to be performed will be described. The pair of inner intervening portions 51, 51 is a cylindrical body along the outer shape of the inner core piece 31m by four plate pieces. Each plate piece is formed in a frame shape in which each piece is connected on one end side. And each inner interposition part 51 and 51 forms the concave engaging part 51e engaged with the 1st end surface interposition part 52a and the 2nd end surface interposition part 52b in both the one end side and other end side of each board piece. Has been. On the other hand, the first end surface interposed portion 52a and the second end surface interposed portion 52b are formed with convex engaging portions 52e that engage with the inner intermediate portions 51, 51. Since the inner interposed portions 51, 51 and the first end surface interposed portion 52a, and the inner interposed portions 51, 51 and the second end surface interposed portion 52b are engaged with each other by the engaging portions 51e, 52e, a plurality of core pieces 31m, The positioning of 32 m and the gap material 31 g can be performed reliably.

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

DESCRIPTION OF SYMBOLS 1 Reactor 2 Coil 2a, 2b Winding part 2r Connection part 2w Winding 3 Magnetic core 31m Inner core piece 31g Gap material 32m Outer core piece 32e Inner end surface 321 Side base part 322 Middle part 322e End surface 5 Insulating intermediate member 50a, 50b Dividing material 51 inner interposition part 51e engagement part 51s slit 52a first end face interposition part 52b second end face interposition part 52e engagement part 52h insertion hole 52d partition part

The partition portion 52d is provided at a position between the inner interposed portions 51 and 51 so as to protrude from the coil side surface of the first end surface interposed portion 52a. The partition portion 52d is split members 50a, 50b of the winding part 2a, when assembled to 2b, the winding portion 2a, is interposed between 2b, hold winding portion 2a, a quarantine status of 2b (FIG. 2 See). By this isolation, the insulation between the winding parts 2a and 2b can be ensured.

The other split member 50b is composed of a second end face interposition part 52b, and, as shown in FIG. 3, two insertion holes 52h and 52h through which the pair of middle parts 322 and 322 of the other outer core piece 32m can be inserted respectively. It is a frame-shaped part of the B-shaped flat plate which it has. The second end surface intervening portion 52b is integrally formed with an engaging portion 52e and a partition portion 52d that engage with an engaging portion 51e formed on the split member 50a on a surface facing the winding portions 2a and 2b. ing. The engaging portion 52e is formed so as to protrude from the surface facing the winding portions 2a and 2b, and this protruding portion (convex portion) is engaged with the concave engaging portion 51e formed in the dividing member 50a. Match. The engaging part 52e is formed corresponding to the engaging part 51e formed in the divided member 50a, and here, it is composed of four curved plate pieces for each of the insertion holes 52h and 52h. The partition part 52d is formed so as to protrude from the surface facing the winding parts 2a and 2b at a position between the insertion holes 52h and 52h.

-Attaching one outer core piece to the first end face interposition part First, one outer core piece 32m is attached to the first end face interposition part 52a of the one split material 50a. Specifically, the split member 50a is attached to the outer core piece 32m so that the pair of middle portions 322 and 322 of the outer core piece 32m are inserted through the insertion holes 52h and 52h of the first end surface interposed portion 52a (FIG. 4). (See the left figure). At this time, one outer core piece 32m is positioned with respect to the first end surface interposed portion 52a (divided material 50a). Further, since the pair of middle portions 322 and 322 are inserted through the insertion holes 52h and 52h, the positioning state between the outer core piece 32m and the first end surface interposed portion 52a (divided material 50a) is stably secured. .

-Attachment of inner core piece and gap material to inner interposition part Next, the laminated body of the some inner core piece 31m and the gap material 31g is inserted inside the inner interposition part 51 among the division | segmentation materials 50a. Specifically, the gap member 31g and the inner core piece 31m are sequentially inserted and stacked inside the inner interposed portion 51. The inner core piece 31m and the outer core piece 32m are laminated so that the gap material 31g is interposed (see the left figure of FIG. 4). As a result, the end surfaces 322e of the middle portions 322 and 322 of the outer core piece 32m come into contact with the gap material 31g. At this time, all of the plurality of inner core pieces 31m and the gap material 31g are accommodated inside the inner interposed portion 51, and a laminate of the inner core piece 31 and the gap material 31g with respect to the inner interposed portion 51 (divided material 50a). Is positioned. Since the end gap material 31g located at the end (the gap material 31g located at the top in the left view of FIG. 4) is also housed inside the inner interposition part 51, it will not fall off from the inner interposition part 51. Absent.

-Attachment of the 2nd end surface interposition part to an inner side interposition part Next, the other split material 50b (2nd end surface interposition part 52b) is attached to the inner side interposition part 51. FIG. More specifically, the engaging portion 51e of the formed split members 50a concave, by fitting a split members 50b formed in the projecting engaging portion 52e, split members 50a, and 50b engage (FIG. (See right figure 4 and figure 3).

-Attachment of the other outer core piece to a 2nd end surface interposition part Finally, the other outer core piece 32m is attached to the other split material 50b (2nd end surface interposition part 52b). Specifically, the outer core piece 32m is attached to the split member 50b so that the pair of middle portions 322 and 322 of the outer core piece 32m are inserted into the insertion holes 52h and 52h of the second end face interposed portion 52b (FIG. 4). (See the right figure). At this time, the other outer core piece 32m is positioned with respect to the second end surface interposed portion 52b (divided material 50b). Further, since the pair of middle portions 322 and 322 are inserted through the insertion holes 52h and 52h, the positioning state between the outer core piece 32m and the second end surface interposed portion 52b (divided material 50b) is stably secured. .

As described above, by assembling the first end surface interposed portion 52a, the second end surface interposed portion 52b, and the inner intermediate portion 51, the positioning of the plurality of core pieces 31m , 32m and the gap material 31g can be facilitated, and the reactor 1 is assembled. Excellent in properties.

In this example, the insulating interposition member 5 includes an integrated member (divided material 50a) in which the first end surface intervening portion 52a and the inner intervening portions 51, 51 are integrally formed, and a second end surface intervening member 52b (divided material). 50b) is made up of two independent products and is easy to handle. The split members 50a, 50b are each engagement portion 51e, since it is engaged 52e, allows a plurality of core pieces 31m, the positioning of 32m and the gap members 31g reliably.

<Embodiment 2>
In the second embodiment, as shown in FIG. 5, the insulating interposition member 5 is composed of a four-part product in which the first end surface interposition portion 52 a, the second end surface interposition portion 52 b, and the pair of inner interposition portions 51, 51 are independent from each other. The form to be performed will be described. The pair of inner intervening portions 51, 51 is a cylindrical body along the outer shape of the inner core piece 31m (FIG. 2) by four plate pieces. Each plate piece is formed in a frame shape in which each piece is connected on one end side. And each inner interposition part 51 and 51 forms the concave engaging part 51e engaged with the 1st end surface interposition part 52a and the 2nd end surface interposition part 52b in both the one end side and other end side of each board piece. Has been. On the other hand, the first end surface interposed portion 52a and the second end surface interposed portion 52b are formed with convex engaging portions 52e that engage with the inner intermediate portions 51, 51. Since the inner interposed portions 51, 51 and the first end surface interposed portion 52a, and the inner interposed portions 51, 51 and the second end surface interposed portion 52b are engaged with each other by the engaging portions 51e, 52e, a plurality of core pieces 31m, The positioning of 32 m and the gap material 31 g can be performed reliably.

Claims (4)

A coil having a pair of winding portions wound around a winding;
A magnetic core having a portion disposed in the winding portion;
An insulating interposed member interposed between the coil and the magnetic core,
The magnetic core is
A plurality of inner core pieces disposed in the winding portion;
A side base portion disposed outside the winding portion and disposed so as to straddle between the winding portions, and a pair of middle portions that protrude from the side base portion and are respectively disposed in the winding portion; A pair of U-shaped outer core pieces in which a base and each of the middle parts are integrally formed;
An end gap material interposed between the inner core piece and each of the pair of outer core pieces,
The insulating interposition member is
A first end face interposition part interposed between one end face in the axial direction of the winding part and one of the pair of outer core pieces, and having two insertion holes through which the middle part can be inserted, and
A second end surface interposed portion interposed between the other end surface in the axial direction of the winding portion and the other of the pair of outer core pieces, and having two insertion holes through which the middle portion can be inserted, and
A reactor comprising a pair of inner interposed portions that are interposed between an inner surface of the winding portion and the inner core piece and the middle portion and house all the inner core pieces and the end gap material.   2. The reactor according to claim 1, wherein the insulating interposition member is a member in which an integrated member in which both the first end surface interposition portion and the inner interposition portion are integrally formed and the second end surface interposition portion are independent.   The reactor according to claim 1, wherein at least one of the first end surface interposed portion and the second end surface interposed portion and the inner intermediate portion include an engaging portion that engages with each other.   The inner interposed portion is a cylindrical body along the outer shape of the inner core piece, and one end side in the axial direction of the cylindrical body is opened at the opposite side of the side surface of the cylindrical body, and the other end side is closed. The reactor of any one of Claims 1-3 in which the slit is formed.

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