JP2018098300A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor capable of improving a cooling efficiency and assemblability.SOLUTION: In a reactor main body having a flat shape in a whole shape, a core 10, a case 4, and a resin member 2 are divided into two vertical directions on a surface orthogonal to a winding axial direction of a coil 5. The core 10 is constructed by an upper core 10a and a lower core 10b. The case 4 is constructed by an upper case 4a housing the upper core 10a and a lower case 4b housing the lower core 10b. The resin member 2 is constructed by an upper resin member 2a that is interposed between the upper core 10a and the upper case 4a while being adhered, and integrates the upper core 10a and the upper case 4a, and a lower resin member 2b that is interposed between the lower core 10b and the lower case 4b while being adhered, and integrates the lower core 10b and the lower case 4a. In the lower case 4b, a one surface of the flat plane is a bottom surface provided onto a cooling surface 7, and an opening part 42 in which the whole surface of the bottom surface of the core 10 is exposed is provided.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a reactor having a reactor body and a case.

  Reactors are used in various applications including drive systems for hybrid vehicles and electric vehicles. For example, a reactor in which a coil is wound around a resin bobbin disposed around a core is often used as a reactor used in an in-vehicle booster circuit.

  As this type of reactor, the core is provided with a resin member covering the periphery of the core in order to insulate it from other members such as a coil. The core covered with the resin member is accommodated in the case with a coil attached to a part of the core.

JP 2013-225688 A

  In the conventional reactor, when the core is cooled, the case is filled with a heat-dissipating filler and solidified through a filling molding portion, which is solidified by a reactor installation surface that also serves as a cooling surface. However, with this technology alone, there is a problem in cooling efficiency in the upper part of the core, that is, in the part far from the installation surface. In addition, in the case of a reactor having a high height with respect to the installation surface, a plurality of members may be interposed from the installation surface to the core, and the thermal resistance increases accordingly, so that the cooling efficiency further decreases.

  Moreover, the reactor main body is comprised in the state in which the resin member which coat | covers the circumference | surroundings of a core was provided, and the reactor main body is accommodated in a case. Thus, since a reactor main body is assembled and accommodated in a case, a clearance gap may arise between a reactor main body and a case. That is, a part of the resin member or the core is in contact with the case, but the other part is not in contact with the case, and both are separated. Therefore, the air in the gap is interposed, and the thermal resistance increases. In order to cope with such a problem, conventionally, after the reactor main body is accommodated in the case, the filler is filled in the case so that the filler is interposed in the gap between the reactor main body and the case, and the thermal resistance A technology for improving the cooling efficiency by lowering the temperature was adopted.

  However, since the reactor is a mass-produced product, it is required to have good assembling ability. The method of filling the case with the above filler is performed at the final stage of the reactor manufacturing, which improves the assembling ability of the reactor. Was not involved in.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a reactor that can improve cooling efficiency and assemblability.

The reactor of this invention has the following structures, It is characterized by the above-mentioned.
(1) A core, a coil attached to a part of the core, a reactor main body having a resin member that covers the core and is insulated from the coil, and a case that houses the reactor main body.
(2) The reactor main body has a flat overall shape, and the core, the case, and the resin member are vertically divided into two in a plane perpendicular to the winding axis direction of the coil. The upper core having a leg to be mounted and a lower core are configured, and the case is configured by an upper case that accommodates the upper core and a lower case that accommodates the lower core, and the resin member is the upper core And an upper resin member that integrates the upper core and the upper case in close contact with each other between the upper case, and an intermediate between the lower core and the lower case, respectively. An upper unit including the upper core, the upper case, and the upper resin member, the lower core, the lower case, and the lower Side tree A lower unit having a member, wherein the coil is attached to and bonded to the legs of the upper core and the lower core, and the flat surface of the lower case is installed on the cooling surface. And an opening for exposing the entire bottom surface of the core is provided on the bottom surface.

The present invention may have the following configuration.
(1) An opening for pulling out the end of the coil is provided on the side surface of the case.
(2) The opening is provided on one side of the case.
(3) The upper core and the lower core are E-shaped cores.
(4) The upper case is provided with a fixing portion for fixing the reactor to the cooling surface.
(5) Provided with a filling molded part having heat dissipation and insulation disposed in the gap in the case,
It is only the filling molding part that is interposed between a part of the inner peripheral surface of the case and the coil.
(6) The upper surface of the upper case opposite to the cooling surface of the case is provided with an opening that exposes the entire upper surface of the core, and includes an upper lid that covers the opening.
(7) The upper surface of the upper case opposite to the cooling surface of the case is provided with an opening that exposes the entire upper surface of the core, and includes an upper lid that covers the opening. It is continuously formed with the same resin as the resin member between the upper case and the upper core.

  A method for manufacturing a reactor according to the present invention is a method for manufacturing a reactor including a core and a case that are divided into upper and lower parts, and a coil that is attached to a part of the core. An opening that exposes the surface is provided, and the divided core and case are set in the mold at a predetermined interval so that the entire surface of the entire surface faces the opening, and the mold is filled with resin. It has the unit manufacturing process to solidify.

  ADVANTAGE OF THE INVENTION According to this invention, the reactor which can improve cooling efficiency and assemblability can be obtained.

It is a perspective view which shows the whole structure of the reactor which concerns on embodiment. It is a disassembled perspective view which shows the whole structure of the reactor which concerns on embodiment. It is a perspective view of a core. It is a disassembled perspective view of a core. It is AA sectional drawing of FIG. It is BB sectional drawing of FIG. It is a perspective view of a case. It is a disassembled perspective view of a case. It is a perspective view of the bottom side of a lower unit. It is a disassembled perspective view of each unit. It is a figure which shows an assembly process. It is a figure which shows a filling process.

  Hereinafter, a reactor according to an embodiment of the present invention will be described with reference to the drawings.

[1. Embodiment]
[1-1. Schematic configuration]
FIG. 1 is a perspective view showing the overall configuration of the reactor according to the present embodiment, and FIG. 2 is an exploded perspective view thereof.

  A reactor is an electromagnetic component that converts electric energy into magnetic energy and stores and discharges it, and is used for voltage step-up / step-down and the like. The reactor according to the present embodiment is a large-capacity reactor used in, for example, a drive system for a hybrid vehicle or an electric vehicle. The reactor is a main component of the booster circuit mounted on these automobiles.

  The reactor includes a reactor main body and a case 4 that houses the reactor main body. The reactor main body includes a core 10 including a magnetic material, a coil 5 attached to a part of the core 10, and an outer periphery of the core 10, and insulates the core 10, the coil 5, and the case 4 from each other. A resin member 2 is provided. Case 4 is slightly larger than the reactor main body, and the reactor main body is accommodated with a gap. And the filling molding part 6 which the resin member 2 or a filler solidifies is provided in this clearance gap.

  The case 4 is provided with a fixing portion 41 projecting in a flange shape on the side surface thereof. A screw is inserted into a screw hole provided in the fixing portion 41, and the reactor is fixed to the cooling surface 7 by screw fastening. The cooling surface 7 is a surface that cools the reactor. The cooling surface 7 is an installation surface of a base that is an installation target of a reactor such as a PCU case, a mission case, a voltage control unit case, or a heat sink.

[1-2. Detailed configuration]
The detailed structure of each part of the reactor of this embodiment is demonstrated using FIGS. In this specification, the z-axis direction shown in FIG. 1 is the “upper” side, and the opposite direction is the “lower” side. In describing the configuration of each member, “lower” is also referred to as “bottom” or “back”. The z-axis direction is the vertical direction of the reactor and the height direction of the reactor.

(core)
FIG. 3 is a perspective view of the core 10. FIG. 4 is an exploded perspective view of the core 10. 5 is a cross-sectional view taken along the line AA in FIG. 1, and FIG. 6 is a cross-sectional view taken along the line BB in FIG.

  The core 10 is configured to include a magnetic body, and the entire shape thereof is flat. As the core 10, a ferrite core, a laminated steel plate, a dust core, or a metal composite core can be used. Here, the core 10 is a metal composite core formed by kneading and molding magnetic powder and resin. As shown in FIGS. 3 and 4, the core 10 of this embodiment includes a pair of upper and lower upper cores 10 a and 10 b that are divided into two on a plane orthogonal to the winding axis direction of the coil 5. This is because the coil 5 is fitted into a later-described middle leg 11 of the core 10 and the coil 5 is attached to a part of the core 10. The upper core 10a and the lower core 10b are both E-shaped cores having the same shape, and the core 10 is configured by abutting each leg portion.

  Specifically, as shown in FIG. 4, the upper core 10 a and the lower core 10 b are positioned on both sides of the columnar middle leg 11 and the middle leg 11, and the cross section is arc-shaped and parallel to the middle leg 11. A pair of outer legs 12 extending and an oval joint plate 13 connecting the middle legs 11 and the pair of outer legs 12 are formed, and a cross section including the legs 11 and 12 forms an E shape.

  The middle leg 11 is located at the center of each core 10a, 10b. The pair of outer legs 12 are arranged facing the same circle with the center of the arc coincident with the center of the middle leg 11. One outer leg 12 has a shorter arc in cross section than the other outer leg 12. The joint plate 13 is a flat plate, and in particular, the surface exposed to the outside of the reactor is a flat surface. The cross-sectional area through which the magnetic flux of the outer leg 12 and the joint plate 13 passes is less than half of the cross-sectional area through which the magnetic flux of the middle leg 11 passes. That is, the cross-sectional area perpendicular to the z-axis of the outer leg 12 is less than half of the cross-sectional area perpendicular to the z-axis of the middle leg 11, and the cross-sectional area perpendicular to the y-axis of the joint leg 13 is z It is less than half of the cross-sectional area orthogonal to the axis.

  The upper core 10a and the lower core 10b are flat. That is, the diameter of the circle which is the cross section of the middle leg 11 is larger than the height in the extending direction of the middle leg 11.

  As shown in FIGS. 5 and 6, the core 10 includes a middle leg portion 101 to which the coil 5 is attached, a pair of outer leg portions 102 located on both sides of the middle leg portion 101, and the middle leg portion 101 and the outer leg portion 101. And a joint plate portion 103 connecting the leg portions 102.

  The middle leg portion 101 is formed in a columnar shape by abutting the middle legs 11 of the upper core 10a and the lower core 10b, and the coil 5 is mounted on the periphery thereof. The middle leg portion 101 is a portion where magnetic flux is generated when the coil 5 is energized.

  The outer leg portion 102 is configured in a columnar shape having a circular cross section by abutting the outer legs 12 of the upper core 10a and the lower core 10b. The pair of outer leg portions 102 are arranged on the same circle so as to face each other with the center of the arc coincident with the center of the middle leg 11, and one outer leg portion 102 is the other outer leg portion 102. The arc is configured to be shorter than that.

  The joint plate portion 103 includes a joint plate 13 of an upper core 10a and a lower core 10b. The outer leg portion 102 and the joint plate portion 103 are yoke portions through which the magnetic flux generated in the middle leg portion 101 passes. The magnetic flux generated in the middle leg portion 101 returns to the middle leg portion 101 from the joint plate portion 103 of the upper core 10a via the pair of left and right outer leg portions 102 and the joint plate portion 103 of the lower core 10b and closes, for example. A magnetic circuit is formed.

  In this embodiment, no spacer is provided between each pair of the upper core 10a and the lower core 10b. However, a spacer may be interposed in the portion. The spacer prevents a decrease in the inductance of the reactor by providing a magnetic gap having a predetermined width. As the material of the spacer, a non-magnetic material, ceramic, non-metal, resin, carbon fiber, or a synthetic material of two or more of these or gap paper can be used.

(coil)
The coil 5 is a conducting wire having an insulating coating. In the present embodiment, the coil 5 is an edgewise coil in which a flat wire is wound in a circular shape. The entire shape of the coil 5 is flat. That is, the diameter of the winding portion around which the conducting wire is wound is shorter than the length of the coil 5 in the winding axis direction. The wire material and winding method of the coil 5 are not limited to the flat wire edgewise coil, but may be in other forms.

  As shown in FIG. 5 and FIG. 6, the coil 5 has an inner leg portion of the core 10 disposed in the air core portion thereof, and the winding axis of the coil 5 and the middle leg portion are parallel to each other. As shown in FIG. 1, both end portions 51 a and 51 b of the coil 5 are drawn out to the side outside of the reactor in parallel with each other from both sides of the outer leg portion having a short arc.

(Case)
FIG. 7 is a perspective view of the case 4. FIG. 8 is an exploded perspective view of the case 4. Case 4 is a housing member that houses the reactor body. The case 4 is made of a light metal having high thermal conductivity, such as an aluminum alloy, and has heat dissipation.

  As shown in FIG. 7, since the core 10 and the coil 5 are flat, the case 4 is also flat as a whole. The case 4 includes a side wall 40 that forms a storage space for the reactor main body, a fixing portion 41 provided on the side wall 40, and an opening 42 provided on the upper surface and the bottom surface.

  The side wall 40 is a wall formed in an annular shape so as to surround the reactor main body. In the present embodiment, as shown in FIG. 7, the overall shape of the side wall 40 is formed in a shape in which three sides of a rectangle and the remaining one side are arcuate. As shown in FIG. 7, a convex portion 401 projecting inward is provided on a part of the inner peripheral surface of the side wall 40. As shown in FIG. 6, the convex part 401 is provided facing two places. One convex portion 401 is provided between one end portions of the outer leg portions 102 facing each other across the middle leg portion 101, and the other convex portion 401 is provided between the other end portions of the outer leg portion 102. The two convex portions 401 are opposed to each other. When the coil 5 is attached to the middle leg portion 101 of the core 10, the convex portion 401 protrudes inward so as not to contact the outer peripheral portion of the winding portion of the coil 5. The convex portion 401 is not covered with the resin member 2 provided on the inner periphery of the case 4, is exposed from the resin member 2, and is close to the coil 5. As a result, the heat dissipation path is shortened, the heat of the coil 5 can be easily transferred to the case 4, and the heat dissipation can be improved.

  As shown in FIGS. 7 and 8, three fixing portions 41 are provided on the outer peripheral surface of the side wall 40, and here, two fixing portions 41 are provided so as to protrude outward in the arc-shaped portion of the side wall 40, One projecting outward is provided on the part that is one side facing the part. Each fixing portion 41 is provided with a screw hole 411. The reactor is fixed to the cooling surface 7 by installing the reactor on the cooling surface 7, inserting a screw into the screw hole 411, and fastening the screw. The fixing portion 41 is provided on the upper case 4a described later.

  Openings 43 for pulling out the end portions 51a and 51b of the coil 5 to the outside of the reactor are provided on the side surfaces of the case 4, respectively. In the present embodiment, the two openings 43 are provided on one side surface of the case 4 so as to be separated from each other by about the diameter of the coil 5.

  The case 4 is configured by being vertically divided into two vertically on a surface orthogonal to the winding axis direction of the coil 5, and here, includes an upper case 4 a and a lower case 4 b. The upper case 4a and the lower case 4b have the same configuration except for the fixing portion 41.

  The upper case 4a accommodates the upper core 10a, and the lower case 4b accommodates the lower core 10b. The upper case 4a and the lower case 4b are provided with openings 42 through which the entire surface of the joint plate 13 of the upper core 10a and the joint plate 13 of the lower core 10b are exposed. In other words, as shown in FIG. 9, the opening 42 of the lower case 4 b is provided on the bottom surface of the lower case 4 b and exposes the entire bottom surface of the core 10. The opening 42 of the upper case 4 a is provided on the upper surface of the upper case 4 a and exposes the entire upper surface of the core 10. By exposing the core 10 in this way, it is possible to prevent the inductance value from being reduced due to the magnetic shielding effect of the case 4.

  As shown in FIG. 7, the opening 42 has an oval shape following the shape of the top surface and the bottom surface of the core 10, and is slightly larger than the top surface and the bottom surface of the core 10. When the upper case 4a and the lower case 4b are combined, the space for housing the reactor main body and the both openings 42 communicate with each other, and the case 4 penetrates vertically.

  As shown in FIG. 8, the upper case 4 a and the lower case 4 b are provided with rectangular cutouts 431 that communicate with the internal space and the outside on one side surface, and the cases 4 a and 4 b are combined. At this time, the openings 43 are formed by combining the notches 431.

(Resin member)
As shown in FIG. 2, the resin member 2 is vertically divided into two on the surface orthogonal to the winding axis direction of the coil 5, and the upper resin member 2 a interposed between the upper core 10 a and the upper case 4 a, A lower resin member 2b interposed between the lower core 10b and the lower case 4b. The upper resin member 2a covers the periphery of the upper core 10a except for the connection surfaces of the legs 11 and 12 with the lower core 10b. The upper resin member 2a is in close contact with both the upper core 10a and the upper case 4a. The lower resin member 2b covers the periphery of the lower core 10a except for the connection surface and bottom surface of each leg 11, 12 with the upper core 10a. The lower resin member 2b is in close contact with both the lower core 10b and the lower case 4b. The degree of close contact between the resin members 2a and 2b is preferably such that the upper core 10a and the upper case 4a, and the lower core 10b and the lower case 4b are in close contact with each other without any gap. The part may contain voids.

  The upper resin member 2a and the lower resin member 2b are made of, for example, a resin such as epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Terephthalate). ing.

  The upper resin member 2a integrates the upper core 10a and the upper case 4a while insulating the upper core 10a and the upper case 4a. The lower resin member 2b integrates the lower core 10b and the lower case 4b while insulating the lower core 10b and the lower case 4b. In other words, as shown in FIG. 10, the upper resin member 2a constitutes the upper unit 1a with the upper core 10a, the upper case 4a and the upper resin member 2a, and similarly, the lower resin member 2b includes the lower core 10b, A lower unit 1b is constituted by the lower case 4b and the lower resin member 2b.

  An upper lid 21 that closes the opening 42 of the upper case 4a extends from the upper resin member 2a. That is, as shown in FIGS. 5 and 6, the upper lid 2 c and the upper resin member 2 a are a single resin member that is seamlessly configured with the same resin. The upper lid 21 covers the upper surface of the upper core 10a exposed from the opening 42 of the upper case 4a.

(Filling part)
The filling molding part 6 is formed by filling and solidifying a filler in the case 4. The filling molding part 6 is formed in a gap in the case 4. Therefore, the filling molding part 6 has a shape that follows the shape of the core 10, the coil 5, the case 4, and the resin member 2. As the filler, a relatively soft resin having a high thermal conductivity is suitable for ensuring the heat dissipation performance of the reactor and reducing the vibration propagation from the reactor body to the case. Moreover, it is preferable that a filler has insulation.

  As shown in FIGS. 5 and 6, the filling molding portion 6 is disposed around the coil 5 and is adjacent to the core 10 through the resin member 2, and the heat of the coil 5 is filled with the filling molding portion 6 and the resin member 2. A heat dissipation route is formed through the core 10 to the cooling surface 7.

  Further, only the filling molding portion 6 is interposed between the coil 5 and the convex portion 401 of the case 4.

[1-3. Reactor manufacturing method]
Next, the manufacturing method of the reactor of this embodiment is demonstrated. The reactor manufacturing method includes (a) a unit manufacturing process, (b) an assembling process, and (c) a filling process.

(a) Unit manufacturing process A unit manufacturing process is a process of manufacturing each unit 1a, 1b. Each unit 1a, 1b is set in a mold by setting the lower case 4b and the lower core 10b, or the upper case 4a and the upper core 10a to each case 4a, 4b, and each core 10a, 1b with a predetermined interval. Each member is formed by pressing each member with a tool, filling the mold with resin, and solidifying the resin. In this setting, a wall, a protrusion, or a jig in the mold is applied to the entire upper surface of the upper core 10a and the entire bottom surface of the lower core 10b. The space between the inner wall of the mold is filled with resin and solidified to form the lower resin member 2b and the upper resin member 2a. As shown in FIG. 10, each case 4a, 4b and each core 10a, 10b Are integrated. Lower resin member 2b is in close contact between lower case 4b and lower core 10b, and upper resin member 2a is in close contact between upper case 4a and upper core 10a. In such integration, the upper surface of the upper core 10a is located on the same plane as the upper surface of the upper case 4a, and is exposed so that the entire surface thereof faces the opening 42 of the upper case 4a. Further, the bottom surface of the lower core 10b is located on the same plane as the bottom surface of the lower case 4b, and is exposed so that the entire surface faces the opening 42 of the lower case 4b.

  However, in the case of the upper unit 1 a, the upper lid 21 is formed by filling the mold with resin and solidifying, and the upper surface of the upper core 10 a is covered with the upper lid 21. Further, the upper lid 21 and the upper resin member 2a are resin members that are continuously formed of the same resin since the upper unit 1a is formed by the insert molding method. The circular opening and the substantially elliptical opening provided in the upper lid 21 are formed when the upper core 10a is fixed with a jig in the mold.

(b) Assembling process The assembling process is a process of assembling the reactor with the lower unit 1b and the upper unit 1a with the coil 5 interposed therebetween. That is, as shown in FIG. 11, the coil 5 is attached to the middle leg of the lower core 10b in the lower unit 1b, and the legs of the cores 10a and 10b are abutted against each other so that the upper unit 1a is in contact with the lower unit 1b. Assemble from above. At that time, an adhesive is applied to each of the legs of the cores 10a and 10b and the opposing surfaces of the cases 4a and 4b to bond the units 1a and 1b. However, the bonding of the legs of the cores 10a and 10b is not essential, and the legs may not be bonded depending on the frequency band in which the reactor is used.

  By this assembly process, an opening 43 is formed on the side surface of the case 4. Further, since at least the upper case 4a and the lower case 4b are bonded, the reactor is sealed except for the opening 43.

(c) Filling Step The filling step is a step of filling the case 4 from the opening 43 into the case 4 and solidifying it. At that time, as shown in FIG. 12, the opening 43 is directed upward to fill the filler. That is, the opening 43 serves to draw out the end portions 51 a and 51 b of the coil 5 and also has a function of injecting a filler into the case 4. In the present embodiment, two openings 43 are provided on one side surface of the case 4, and the case 4 is sealed at a portion other than the opening 43, so that the filled filler leaks from other than the opening 43. Can be prevented. In FIG. 12, the filler is injected from both openings 43, but it may be from only one of them.

[1-4. Action / Effect]
(1) The reactor of this embodiment accommodates the reactor main body which has the core 10, the coil 5 with which a part of core 10 is mounted | worn, and the resin member 2 which coat | covers the core 10 and is insulated from the coil 5, and a reactor main body The reactor body has a flat overall shape, and the core 10, the case 4, and the resin member 2 are vertically divided into two on a plane orthogonal to the winding axis direction of the coil 5, and the core 10 The upper core 10a and the lower core 10b having middle legs on which the coil 5 is mounted are configured. The case 4 includes an upper case 4a that houses the upper core 10a and a lower case 4b that houses the lower core 10b. I did it.

  The resin member 2 is interposed between the upper core 10a and the upper case 4a in close contact with each other, and the upper resin member 2a that integrates the upper core 10a and the upper case 4a, the lower core 10b, and the lower case 4b. An upper unit having an upper core 10a, an upper case 4a, and an upper resin member 2a. The upper unit is composed of a lower resin member 2b that is in close contact with the lower core 10b and the lower case 4b. 1a and a lower unit 1b having a lower core 10b, a lower case 4b, and a lower resin member 2b are attached by attaching a coil 5 to middle legs of the upper core 10a and the lower core 10b. In 4b, the flat one surface is used as a bottom surface installed on the cooling surface 7, and an opening 42 through which the entire bottom surface of the core 10 is exposed is provided on the bottom surface.

  Thereby, while being able to cool directly from the whole bottom face of the core 10 exposed from the opening part 42, since the whole shape of a reactor is flat, the distance from the bottom part of the reactor installed on the cooling surface 7 to the upper part Is short, and the cooling efficiency up to the top of the reactor can be improved. That is, since the core 10 is directly cooled from the entire bottom surface, the cooling area is large and the overall shape of the reactor is flat. Therefore, the heat radiation route from the bottom to the top of the reactor can be shortened, and the core 10 can be shortened from the bottom to the top. Overall cooling is possible. In addition, by flattening the shape of the reactor, it is possible to prevent an increase in thermal resistance due to the presence of a plurality of members from the bottom of the reactor to the top.

  In addition, the resin member 2 that insulates the core 10 and the coil 5 is divided into two parts in the vertical direction, and the coil 5 is interposed in the lower unit 1b by providing a function as a coupling member constituting each unit 1a, 1b. Since the upper unit 1a is assembled, the assemblability can be improved. That is, since each unit 1a, 1b is configured by using the resin member constituting the reactor main body at the stage where the reactor main body is assembled, not the filler used in the final stage of the reactor production, the assemblability is improved. improves. Moreover, since the resin members 2a and 2b are in close contact with the cores 10a and 10b and the cases 4a and 4b, the cooling efficiency can be improved. That is, it is possible to suppress an increase in thermal resistance due to the presence of air due to a gap generated between the upper core 10a and the upper case 4a and between the lower core 10b and the lower case 4b.

For example, when comparing the heat transfer coefficient depending on the presence or absence of the resin member 2 when the flatness of the contact surface between the core 10 and the case 4 is 0.1, the resin member 2 having a thickness of 1 mm is between the members 10 and 4. In some cases, the heat transfer coefficient is 300 W / m ² · K, while in the absence of the resin member 2, the heat transfer coefficient is 200 W / m ² · K, and the resin member 2 improves the adhesion. Heat transfer is easier and cooling efficiency is improved.

  Moreover, since the resin member 2 bears the cooling function that the filler has taken on, the amount of the filler filled in the case 4 can be reduced. Since the cost of the filler is higher than that of the resin constituting the resin member 2, there is an advantage that the manufacturing cost can be reduced.

  As described above, according to the present embodiment, both the cooling efficiency and the assemblability can be improved.

(2) An opening 43 for drawing out the end portions 51 a and 51 b of the coil 5 is provided on the side surface of the case 4. Thereby, a reactor can be reduced in size. That is, in the conventional reactor, the end of the coil is pulled out above the reactor, and the winding of the coil cannot be penetrated through the core. Therefore, it is necessary to avoid the core and other members and pull out upward. It was. For this reason, an opening for pulling out the end of the coil has to be provided outside the core and coil, and the reactor has become larger, so it has not been possible to meet the demand for use in environments with severe design conditions. . On the other hand, according to the present embodiment, by providing the opening 43 for drawing out the coil end portions 51a and 51b on the side surface of the case 4, the coil end portions 51a and 51b are prevented from being enlarged. It can be pulled out, and a reactor that can be installed even in a space-constrained environment can be obtained.

(3) The opening 43 is provided on one side surface of the case 4. Thereby, when filling the case 4 with the filler, the opening 43 can be used as an inlet for the filler. Further, in the manufacturing process of the reactor, the opening 43 can be filled upward so that the filler can be filled, and even the side surface of the case 4 has openings for drawing the coil end portions 51a and 51b on different side surfaces. Compared with the case where 43 is provided, it is not necessary to worry about the leakage of the filler, so that productivity can be improved. Thus, the advantages of the manufacturing process as well as the downsizing of the reactor can be enjoyed.

(4) The upper core 10a and the lower core 10b are E-shaped cores. Thereby, size reduction and height reduction of a reactor can be achieved. That is, since the E-shaped core is used, the flow of the magnetic flux is divided from the middle leg portion 101 of the E shape to the left and right by the joint plate portion 103, and from the outer leg portion 102 via the joint plate portion 103 to the middle leg portion 101. Will join. Thus, since the flow of magnetic flux is divided into two, the cross-sectional area through which the magnetic flux of the outer leg 12 passes may be less than half the cross-sectional area through which the magnetic flux of the middle leg 11 passes. Thus, if the cross-sectional area required for the outer leg 12 is determined, the thickness of the outer leg 12 can be reduced by increasing the length of the arc of the outer leg 12. As a result, downsizing can be achieved. The cross-sectional area through which the magnetic flux of the joint plate 13 passes may be less than half of the cross-sectional area through which the magnetic flux of the middle leg 11 passes. Thus, if the cross-sectional area required for the joint plate 13 is determined, the thickness of the joint plate 13 can be reduced. As a result, it is possible to reduce the height. For example, when a ring-shaped core is formed by abutting U-shaped cores, the magnetic flux is not diverted, so the section where the coil is mounted and the yoke section where the coil is not mounted must have the same cross-sectional area. However, while the width and height are increased, the size and height can be reduced by making the shape E-shaped.

  Moreover, since the joint plate 13 secures a necessary cross-sectional area by reducing the thickness, the width in the x-axis direction is widened, so that the area of the bottom surface of the core is widened. In other words, it is possible to efficiently secure the cooling area on the cooling surface 7.

(5) The upper case 4 a is provided with a fixing portion 41 for fixing the reactor to the cooling surface 7. Thereby, since the reactor main body can be fixed so as to be suppressed from the upper case 1a, problems such as the reactor main body detaching from the case 4 and popping out can be prevented. That is, the reactor body can be firmly fixed in the case 4 and the vibration resistance can be improved. In addition, since the close contact between the bottom surface of the core 10 and the cooling surface 7 can be stably fixed, the cooling efficiency can be maintained even when the reactor is used for a long time.

(6) The filling portion 6 having the heat radiation and insulating properties disposed in the gap in the case 4 and having a portion between the inner peripheral surface of the case 4 and the coil 5 is filled. Only the molded part 6 was used. Thereby, while insulating between the case 4 and the coil 5 and no other member interposed, the coil 5 can be efficiently cooled without increasing the thermal resistance.

(7) The upper surface of the upper case 4a opposite to the cooling surface 7 of the case 4 is provided with an opening 42 that exposes the entire upper surface of the core 10, and the upper lid 21 that covers the opening 42 is provided. . Thereby, the rust of the upper surface of the core 10 can be prevented. In addition, it is possible to prevent the core 10 from being chipped for some reason and releasing the core piece to the outside of the reactor. Therefore, it is possible to prevent foreign matters from being mixed into other parts of the core piece due to chipping of the core 10, and a highly reliable reactor can be obtained.

(8) The upper surface of the upper case 4a opposite to the cooling surface 7 of the case 4 is provided with an opening 42 through which the entire upper surface of the core 10 is exposed, and the upper cover 21 covering the opening 42 is provided. The upper resin member 2a between the upper case 4a and the upper core 10a is formed continuously with the same resin. In addition to the effect (7), the upper lid 21 is continuously formed of the same resin as the resin member by a molding method, so that the number of manufacturing steps can be reduced.

(9) The method for manufacturing a reactor according to the present embodiment is a method for manufacturing a reactor having a core 10 and a case 4 that are divided vertically and a coil 5 that is attached to a part of the core 10. Is provided with an opening 42 that exposes the entire surface of the core 10, and the upper core 10a, the lower core 10b, and the upper core that are divided at predetermined intervals so that the entire surface of the core 10 faces the opening 42. The case 4a and the lower case 4b are set in a mold, and the mold is filled with a resin and has a unit manufacturing process for solidifying.

  Thereby, while being able to aim at insulation of case 4 and core 10, man-hours can be decreased rather than aiming at the insulation concerned by another member. Furthermore, since the reactor can be configured by interposing the coil 5 between the upper unit 1a and the lower unit 1b, the assemblability of the reactor itself can be improved.

[2. Other Embodiments]
The present invention is not limited to the above embodiment, and includes other embodiments described below. In addition, the present invention also includes a form in which all or any one of the radical removal embodiment and the following other embodiments is combined. Furthermore, various omissions, replacements, and modifications can be made to these embodiments without departing from the scope of the invention, and modifications thereof are also included in the present invention.

(1) In the embodiment, the upper unit 1a and the lower unit 1b are adhered and sealed with an adhesive, but a sealing material such as rubber such as an O-ring or a gasket is interposed between the upper case 4a and the lower case 4b. You may make it seal by interposing.

(2) In the embodiment, the upper lid 21 is formed integrally with the upper resin member 2a by the insert molding method, but may be provided as a separate member. Further, although the upper lid 21 is made of resin, it may be made of a metal having heat dissipation properties. For example, the upper case 4a may be a bottomed case that closes the opening 42 of the upper case 4a. Further, the upper lid 21 may be eliminated, and the cooling member or the cooling surface may be brought into close contact with the upper surface of the upper core 10a exposed from the opening 42 of the upper case 4a to cool the core 10 from above. This is effective in an environment where the temperature of the core 10 is likely to rise.

(3) In the embodiment, the core 10 is composed of the upper cores 10a and 10b having an E-shaped cross section. However, the upper cores 10a and 10b are limited to have an E-shaped cross section as long as the coil 5 can be attached to a part thereof. Alternatively, other shapes such as a U shape and an I shape may be used.

1a upper unit 1b lower unit 10 core 10a upper core 10b lower core 11 middle leg 12 outer leg 13 joint plate 101 middle leg part 102 outer leg part 103 joint plate part 2 resin member 2a upper resin member 2b lower resin member 21 upper lid 4 Case 4a Upper case 4b Lower case 40 Side wall 401 Protruding part 41 Fixing part 411 Screw hole 42 Opening part 43 Opening 431 Notch 5 Coils 51a, 51b End part 6 Filling molding part 7 Cooling surface

Claims (9)

A core, a coil mounted on a part of the core, and a reactor main body having a resin member that covers the core and is insulated from the coil;
A case for housing the reactor body;
With
The reactor body has a flat overall shape,
The core, the case, and the resin member are vertically divided into two in a plane perpendicular to the winding axis direction of the coil,
The core is composed of an upper core and a lower core having legs on which the coil is mounted,
The case includes an upper case that houses the upper core and a lower case that houses the lower core,
The resin member is in close contact with and interposed between the upper core and the upper case, and is integrated between the upper core member and the lower case, and the upper resin member that integrates the upper core and the upper case. It is in close contact with each other, and is composed of a lower resin member that integrates the lower core and the lower case,
An upper unit having the upper core, the upper case, and the upper resin member;
The lower core, the lower case, and the lower unit having the lower resin member are attached to the legs of the upper core and the lower core with the coil attached thereto,
The lower case has the flat one surface as a bottom surface installed on the cooling surface, and the bottom surface is provided with an opening that exposes the entire bottom surface of the core,
Reactor characterized by. An opening for pulling out the end of the coil is provided on the side surface of the case.
The reactor according to claim 1. The opening is provided on one side of the case;
The reactor according to claim 2. The upper core and the lower core are E-shaped cores;
The reactor according to any one of claims 1 to 3. The upper case is provided with a fixing portion for fixing a reactor to the cooling surface,
The reactor according to claim 4. A filling molded part having heat dissipation and insulation disposed in the gap in the case,
It is only the filling molding part that is interposed between a part of the inner peripheral surface of the case and the coil,
The reactor according to any one of claims 1 to 5. The upper surface of the upper case opposite to the cooling surface of the case is provided with an opening that exposes the entire upper surface of the core,
Comprising an upper lid covering the opening;
The reactor according to any one of claims 1 to 6. The upper surface of the upper case opposite to the cooling surface of the case is provided with an opening that exposes the entire upper surface of the core,
An upper lid covering the opening;
The upper lid is formed of the same resin as the resin member between the upper case and the upper core;
The reactor according to any one of claims 1 to 6. A method of manufacturing a reactor having a core and a case divided into upper and lower parts, and a coil attached to a part of the core,
The case is provided with an opening that exposes the entire surface of the core.
A unit manufacturing process in which the divided core and case are set in a mold at a predetermined interval so that the entire surface of the entire surface faces the opening, and the mold is filled with resin and solidified. ,
A method for manufacturing a reactor, characterized in that

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