JP6179701B2 - Reactor, converter, and power converter - Google Patents

Description

  The present invention relates to a reactor used as a component of a power conversion device such as an in-vehicle DC-DC converter mounted on a vehicle such as a hybrid vehicle, a converter including the reactor, and a power conversion device including the converter. is there. In particular, the present invention relates to a reactor excellent in 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. For example, Patent Document 1 discloses a coil having a pair of coil elements arranged side by side as a reactor used in a converter mounted on a vehicle such as a hybrid vehicle, and a pair of inner core portions in which the coil elements are respectively disposed. (Intermediate core) and a magnetic core formed in an annular shape by a pair of outer core portions (end cores) where no coil is disposed, and a cylindrical bobbin interposed between the coil and the magnetic core to enhance the insulation between them And a frame-shaped bobbin.

  As described in Patent Document 1, for example, the inner core portion is formed by alternately laminating a thin steel plate such as a silicon steel plate, a core piece made of a compacted body, and a plate-like gap material made of ceramics. It is comprised from the laminated body laminated | stacked and the form comprised from the said core piece is mentioned for an outer core part. The cylindrical bobbin is interposed between an inner core portion formed of the laminate and a coil element, and the frame bobbin is interposed between an end surface of the coil element and an outer core portion (Patent Literature). 1).

A reactor having the above configuration is assembled as follows.
(1) The above-described core piece and gap material are laminated to form the inner core portion.
(2) A cylindrical bobbin is disposed on the outer periphery of the inner core portion.
(3) Two inner core parts provided with a cylindrical bobbin are produced and inserted into coil elements, respectively.
(4) The core pieces constituting the frame-shaped bobbin and the outer core part are arranged so as to sandwich the two inner core parts arranged in parallel by being arranged in the coil element, and the inner core part and the outer core part are appropriately arranged. Join.

JP 2010-263075 A

  As described above, the conventional reactor has a problem that the number of parts is large and the assembly workability is not good. In particular, in recent years, with the rapid development of hybrid vehicles and electric vehicles, the demand for reactors continues to expand, and it is desired to improve the assembly workability of the reactors.

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a reactor having excellent assembly workability. Another object of the present invention is to provide a converter using the reactor of the present invention and a power converter using the converter.

  The reactor of the present invention includes a coil having a pair of coil elements connected in parallel and an annular magnetic core inserted into the coil element, and the magnetic core is disposed inside the coil element. And a pair of outer core portions that are exposed from the coil element and form a closed magnetic path with the inner core portion. The reactor according to the present invention includes a pair of core parts obtained by integrating a set of one inner core part and one outer core part with a coating resin, and is provided in both core parts by combining the pair of core parts. The cores are arranged in a ring shape to form the magnetic core.

  With the above-described configuration, it is possible to omit the work of assembling the bobbin to the magnetic core, which has been necessary in the past, and to complete the reactor only by combining the coil and the pair of core parts. As a result, the reactor of the present invention is a reactor that is superior in assembly workability compared to conventional reactors.

  As one form of the reactor of the present invention, the coating resin includes a base portion that covers the outer core portion, a peripheral surface covering portion that covers the peripheral surface of the inner core portion, a peripheral surface covering portion that covers the peripheral surface of the inner core portion, A form provided with the engagement cylinder part parallel to a surface covering part can be mentioned. In this case, the peripheral surface covering portion includes a base covering portion extending from the base portion over a predetermined length, and an engaging portion that is continuous with the base covering portion and has an outer diameter smaller than the outer diameter of the base covering portion. And By doing so, when a pair of core parts is combined, the engaging part of one core part fits into the engaging cylinder part of the other core part, and the engaging part of the other core part is the one core It fits into the engagement cylinder of the part.

  By providing the engaging part and the engaging tube part on both core parts, the work of combining both core parts can be facilitated. Moreover, since the mutual positional relationship of both core components can be uniquely determined by the said engaging part and an engaging cylinder part, even if a reactor is mass-produced, it is in the positional relationship between each core part in each reactor. Difficult to occur.

  As one form of this invention reactor, it is mentioned that a base is set as the form provided with the partition part which protrudes from a base between a surrounding surface coating | coated part and an engagement cylinder part.

  By providing the partition part, when the coil is fitted into the core part, insulation between the two coil elements provided in the coil can be reliably ensured.

  As one form of this invention reactor, the lower surface of an outer core part can mention the structure exposed from the base part of coating resin.

  If the lower surface of the outer core portion is exposed from the lower surface of the base portion as in the above configuration, the heat of the outer core portion can be efficiently radiated to the other member when the core component is attached to the other member. it can. In addition, as said other member, when providing the installation object of reactors, such as a cooling base, or the heat sink mentioned later, the heat sink can be mentioned.

  As one form of this invention reactor, it is mentioned that a core component is set as the form provided with the attaching part for attaching a core component to another member. In that case, it is preferable that the attachment portion is constituted by a coating resin that constitutes the core component, and a cylindrical body that is held by the coating resin and allows a fixing member that fixes the core component to another member to be inserted.

  By forming the attachment portion, the core component can be easily fixed to the other member. Moreover, in the said structure, since the cylindrical body is arrange | positioned at the attaching part, the attaching part exhibits proof strength with respect to the clamping force of a fixing member. The cylindrical body may be made of a material having higher rigidity than the coating resin. For example, the cylindrical body is preferably made of a metal (alloy) or the like.

  As one form of the reactor of the present invention, a non-magnetic metal heat sink on which a combination of a coil and a pair of core parts is placed, and an insulating resin disposed between the combination and the heat sink It is mentioned that it is set as the form provided with the joining layer containing.

  By setting it as a structure provided with a metal heat sink, the heat generated in the reactor can be efficiently radiated to the installation target of the reactor. In recent years, reactors used in hybrid vehicles and the like are often used at high frequencies and large currents, and the amount of heat generated by the coils and magnetic cores of the reactors tends to increase. On the other hand, the reactor of the present invention including a metal heat sink is configured to efficiently dissipate the heat generated in the reactor, so that even when used with a large current of 100 A or more, for example, the operation thereof Is less likely to become unstable. In addition, the insulation with the combination body and heat sink in this invention reactor is ensured by the joining layer containing insulating resin.

  As one form of this invention reactor, it is mentioned that a heat sink has a form provided with the insertion hole which penetrates the fixing member which fixes a reactor to installation object.

  By forming the insertion hole in the heat radiating plate, the reactor can be easily attached to an installation target such as a cooling base.

  As one form of this invention reactor provided with the heat sink provided with the said insertion hole, and a joining layer, the insertion hole of a heat sink overlaps with the cylindrical body with which the attachment part of a core component is equipped, and a core component and a heat sink are integrated. It is mentioned that it is set as the form comprised so that it can fix to installation object.

  With the above configuration, if the fixing member is inserted into the cylindrical body of the core part, it is also inserted into the insertion hole of the heat radiating plate, so the assembly and the heat radiating plate are integrally fixed to the installation target by the fixing member. be able to.

  The reactor of the present invention can be suitably used as a component part of a converter. The converter of the present invention includes a switching element, a drive circuit that controls the operation of the switching element, and a reactor that smoothes the switching operation, and converts the input voltage by the operation of the switching element. The form whose reactor is this invention reactor is mentioned. This converter of the present invention can be suitably used as a component part of a power converter. As a power converter of the present invention, a converter for converting an input voltage and an inverter connected to the converter for converting direct current and alternating current to each other and driving a load with the power converted by the inverter And the converter is a converter according to the present invention.

  The converter of the present invention using the reactor of the present invention that is excellent in assembling workability and the power converter of the present invention are excellent in productivity. As a result, it contributes to the improvement of the productivity of equipment (for example, a vehicle such as a hybrid car) provided with these.

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

1 is a schematic perspective view of a reactor according to a first embodiment. 1 is an exploded perspective view of a reactor according to a first embodiment. It is a disassembled perspective view of the combination body with which the reactor which concerns on Embodiment 1 is equipped. FIG. 3 is a schematic perspective view of a pressing member provided in the reactor according to the first embodiment. 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit which shows an example of this invention power converter device provided with this invention converter.

  Hereinafter, embodiments of the present invention will be described more specifically. The same reference numerals in the figure indicate the same names.

<Embodiment 1>
The reactor 1 of Embodiment 1 is demonstrated with reference to FIGS. A reactor 1 shown in FIGS. 1 and 2 includes a coil 2 including a pair of coil elements 2A and 2B, and a magnetic core 3 that is disposed inside and outside the coil 2 to form a closed magnetic path (see FIG. 3; FIGS. The magnetic core 3 has a configuration in which a combination body 10 with an invisible appearance is disposed on the heat sink 6. The feature of the reactor 1 is that the magnetic core 3 is configured by combining a pair of core components 4A and 4B. Hereinafter, each structure of the reactor 1 of this Embodiment 1 is demonstrated in detail.

≪Union body≫
As shown in the exploded perspective view of FIG. 3, the combined body 10 of this embodiment includes a coil 2 and a magnetic core 3 assembled to the coil 2.

〔coil〕
The coil 2 includes a pair of coil elements 2A and 2B and a coil element connecting portion 2r that connects both the coil elements 2A and 2B. The coil elements 2A and 2B are formed in a hollow cylindrical shape with the same number of turns and the same winding direction, and are arranged side by side so that the axial directions are parallel to each other. The coil element connecting portion 2r is a U-shaped portion that connects the coil elements 2A and 2B on the other end side of the coil 2 (right side in FIG. 3). The coil 2 may be formed by spirally winding a single winding without a joint. Alternatively, the coil elements 2A and 2B may be formed by separate windings, and the coil elements 2A and 2B may be formed. You may form by joining the edge parts of a coil | winding by soldering or crimping | compression-bonding.

  As the coil 2, 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, or an alloy thereof can be suitably used. In the present embodiment, the conductor is made of a copper rectangular wire, and the insulation coating is made of a coated rectangular wire made of enamel (typically polyamideimide), and each of the coil elements 2A and 2B uses the covered rectangular wire as edgewise. It is a wound edgewise coil. Moreover, although the end face shape of each coil element 2A, 2B is made into the shape which rounded the rectangular corner | angular part, end face shape can be changed suitably, such as circular shape.

  Both end portions 2a and 2b of the coil 2 are extended from the turn forming portion and connected to terminal members 9A and 9B embedded in a pressing member 8 described later (see FIG. 1). An external device (not shown) such as a power source for supplying power is connected to the coil 2 via the terminal members 9A and 9B.

[Magnetic core]
The magnetic core 3 is formed by annularly combining a pair of inner core portions 31, 31 disposed inside the coil elements 2 </ b> A, 2 </ b> B and a pair of outer core portions 32, 32 exposed from the coil 2. The Here, in the present embodiment, these core parts are used in the form of a core part 4A and a second core part 4B integrated with a coating resin. These first core parts 4A and 4B are members of the same shape, and if the first core part 4A is rotated 180 ° in the horizontal direction, it becomes the second core part 4B. Accordingly, each part of the second core component 4B is denoted by the same reference numeral as that of the first core component 4A, and hereinafter, the first core component 4A will be described as an example.

[Core parts]
As shown in FIG. 3, the first core component 4A is a substantially L-shaped member in which an assembly of one inner core portion 31 and one outer core portion 32 is integrated with a coating resin 5A (note that As shown in FIG. 3, both the core parts 31 and 32 are almost covered with the coating resin 5A, and it is difficult to confirm from the appearance). Simply speaking, the first core component 4A is a member in which the inner core portion 31, the outer core portion 32, the cylindrical bobbin, and the frame bobbin are integrally formed. That is, the coating resin 5A may be considered to play the same role as the bobbin in the conventional configuration.

  The inner core portion 31 alternately connects core pieces 31m made of a substantially rectangular parallelepiped magnetic material and gap material 31g having a lower magnetic permeability than the core pieces 31m, as indicated by a dotted circle in the lower right of FIG. This is a laminated columnar body.

  On the other hand, the outer core portion 32 is, for example, a columnar core piece whose upper surface is substantially dome-shaped, as shown by a dotted circle in the upper left of FIG. In the present embodiment, the outer core portion 32 is partially covered with the coating resin 5A. The portion of the outer core portion 32 that is not covered with the coating resin 5A will be described in the description of the coating resin 5A.

  The covering resin 5A that integrates the inner core portion 31 and the outer core portion 32 includes a base portion 51A, a peripheral surface covering portion 52A, and an engaging cylinder portion 53A. The peripheral surface covering portion 52A and the engaging cylinder portion 53A protrude in a state of being juxtaposed from one surface side of the base portion 51A.

  The base portion 51 </ b> A covers all portions of the outer core portion 32 other than the portion corresponding to the inside of the peripheral surface covering portion 52 </ b> A and the engagement tube portion 53 </ b> A and the portion corresponding to the lower surface of the outer core portion 32. Here, since the inner core portion 31 is disposed in the peripheral surface covering portion 52A as described later, the outer core portion 32 is not exposed from this portion.

  51 A of base parts are provided with the partition part 519 which protrudes from 51 A of base parts between 52 A of surrounding surface coating parts, and the engagement cylinder part 53A. The partition portion 519 is disposed between the two coil elements 2A and 2B of the coil 2 fitted into the core parts 4A and 4B, and is for maintaining the separated state of the two coil elements 2A and 2B. As a result, insulation between the two coil elements 2A and 2B can be reliably ensured.

  Further, the base 51A includes a mounting portion 510 at a position that does not overlap with the outer core portion 32 when the core component 4A is viewed from above. The attachment portion 510 is a portion for attaching the core component 4A to a heat radiating plate 6 (see FIG. 2), which will be described later, and as shown in the lower left dotted circle in FIG. 3, the coating resin 5A and the coating resin It is comprised with the cylindrical body 511 hold | maintained by 5A. In this embodiment, as shown in FIG. 2, a fixing member 10 </ b> C such as a bolt is inserted through the hole of the attachment portion 510 (inside the cylindrical body 511 of FIG. 3) and screwed to the attachment hole 61 h of the heat radiating plate 6. Thus, the core parts 4A and 4B (that is, the combined body 10) are fixed to the heat radiating plate 6. Here, the cylindrical body 511 may be made of a material having higher rigidity than the coating resin 5A, for example, an alloy such as stainless steel, and the mounting portion 510 is deformed / damaged by the tightening force of the fixing member 10C. This can be suppressed.

  As shown in FIG. 3, the circumferential surface covering portion 52 </ b> A covers the circumferential surface of the inner core portion 31 described above over almost the entire length in the longitudinal direction. That is, the peripheral surface covering portion 52A serves as a cylindrical bobbin in the conventional configuration. The peripheral surface covering portion 52A includes a base covering portion 523 extending from the base portion 51A over a predetermined length, and an engaging portion 527 continuous to the base covering portion 523. The outer diameter of the engaging portion 527 is smaller than the outer diameter of the base covering portion 523, and the inner diameter of the engaging portion 527 is equal to the inner diameter of the base covering portion 523. That is, the engaging portion 527 is formed thinner than the base covering portion 523, and the engaging portion 527 can be inserted into the engaging cylinder portion 53A of the second core component 4B facing the first core component 4A. It is like that. Therefore, when the first core part 4A and the second core part 4B are brought close to each other, the engaging cylinder part 53A and the engaging part 527 of both the core parts 4A and 4B are fitted together, and both the core parts 4A and 4B are annularly formed. It becomes a connected state.

  Here, as already described, the outer core part 32 is exposed inside the cylinder of the engaging cylinder part 53A fitted with the engaging part 527 (the engaging cylinder part 53A of the core component 4B in FIG. 3). See section). Therefore, when the first core component 4A and the second core component 4B are combined, the inner core portion 31 is connected to the outer core portion 32 via the gap material 31g. Thus, the magnetic core 3 in which the pair of inner core portions 31 and 31 and the pair of outer core portions 32 and 32 are annularly arranged by simply fitting the first core component 4A and the second core component 4B together. Is formed.

  Examples of the constituent material of the coating resin 5A described above include heat such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), nylon 6, nylon 66, and polybutylene terephthalate (PBT) resin. A plastic resin can be used.

[Material of core piece]
Each core piece constituting the inner core portion 31 and the outer core portion 32 includes a compacted body using a soft magnetic powder represented by an iron group metal such as iron or an alloy thereof, or a soft magnetic powder. A molded cured body made of a resin, a laminated body in which a plurality of magnetic thin plates (for example, electromagnetic steel sheets) having an insulating coating are laminated, and the like can be used.

  The core pieces 31m constituting the inner core portions 31 and 31 and the outer core portions 32 and 32 may have different magnetic characteristics. For example, the magnetic properties of the core piece 31m and the outer core portion 32 may be made different from each other by using different materials. The core piece 31m may be a molded and hardened body, and the outer core portion 32 may be a green compact. By doing so, the magnetic characteristics of the two may be made different. In general, the amount of magnetic powder contained in the molded and hardened body tends to be smaller than that of the green compact, so that “the relative permeability of the molded hardened body <the relative permeability of the green compact”. Therefore, if the inner core portion 31 is a molded hardened body and the outer core portion 32 is a compacted molded body, the magnetic core 3 (reactor 1) that is difficult to be magnetically saturated even when used with a large current can be obtained. When the inner core portion is formed of a molded cured body, the inner core portion may be formed of one core piece made of the molded cured body and two gap members bonded to both end faces of the core piece. good.

≪Heat sink≫
The heat sink 6 is a plate-like member that functions as a heat dissipation path from the combination 10 to the installation target while supporting the combination 10, and is larger than the installation target side surface of the combination 10 in the present embodiment. Specifically, as shown in FIG. 2, one surface side (upper side of the paper surface) of the heat radiating plate 6 is a mounting surface on which the assembly 10 is mounted, and the other surface side (lower side of the paper surface) of the heat radiating plate 6 is the reactor 1. It is the attachment surface to the installation object (not shown) which cools.

  The heat radiating plate 6 is preferably composed of a nonmagnetic metal from the viewpoints of magnetic flux shielding and thermal conductivity. As a specific metal, for example, aluminum (thermal conductivity: 237 W / m · K) or an alloy thereof is preferable. In addition, magnesium (156 W / m · K) or an alloy thereof, copper (398 W / m · K), The alloy may be silver (427 W / m · K), an alloy thereof, iron, or austenitic stainless steel (for example, SUS304: 16.7 W / m · K). When the aluminum, magnesium, or an alloy thereof is used, the reactor 1 can be reduced in weight. In particular, aluminum and its alloys are excellent in corrosion resistance, and magnesium and magnesium alloys are excellent in vibration damping properties. The heat radiating plate 6 composed of these metal materials can be formed by plastic working such as press working as well as casting such as die casting.

  The thickness of the heat sink 6 can be appropriately selected depending on the material of the heat sink 6. For example, when the heat radiating plate 6 is made of a nonmagnetic metal such as aluminum, the heat radiating plate 6 having sufficient strength and magnetic flux shielding properties can be obtained when the thickness of the heat radiating plate 6 is about 1 to 5 mm.

  At the four corners of the heat radiating plate 6, outside the joining region with the assembly 10, there are provided core component mounting holes 61h for fixing the core components 4A and 4B to the heat radiating plate 6 by fixing members (for example, bolts) 10C. It has been. Here, the core component attachment hole 61h in the present embodiment also serves as an insertion hole for fixing the reactor 1 to an installation target such as a cooling base. Therefore, the core components 4A and 4B can be fixed to the heat sink 6 and the heat sink 6 can be fixed to the installation target by the fixing member (for example, bolt) 10C. Of course, there may be an insertion hole for fixing the reactor 1 to the installation object independently of the core component mounting hole 61h.

  In addition, the heat radiating plate 6 is provided with presser member mounting holes 6Ah and 6Bh for mounting a presser member 8 to be described later. The pressing member mounting holes 6Ah and 6Bh are also provided outside the joint region of the combined body 10.

≪Junction layer≫
The bonding layer 7 is formed between a portion of the combined body 10 facing the heat sink 6 (that is, the lower surfaces of the coil elements 2A and 2B and the lower surface of the outer core portion 32) and the heat sink 6 to form the combined body. 10 is a layer to be joined to the heat sink 6.

  In the present embodiment, an insulating sheet 7A for ensuring insulation between the radiator plate 6 made of a nonmagnetic metal and the combined body 10, and an adhesive sheet 7B for bonding the combined body 10 on the insulating sheet 7A, Thus, the bonding layer 7 was formed. The insulating sheet 7A is attached to the heat sink 6 with an adhesive or the like. On the other hand, both surfaces of the adhesive sheet 7B are sticky and soft, and have a function of firmly attaching the combined body 10 having a complicated uneven shape to the insulating sheet 7A.

  The insulation sheet 7A is required to have a predetermined withstand voltage characteristic (2.5 kV / 50 μm or more in the reactor 1). The insulating sheet 7A preferably has excellent thermal conductivity so that heat generated in the coil 2 (coil elements 2A and 2B) can be effectively transmitted to the heat radiating plate 6, and the thermal conductivity is high. The more preferable. For example, the thermal conductivity is 0.1 W / m · K or more, preferably 0.15 W / m · K or more, more preferably 0.5 W / m · K or more, further preferably 1 W / m · K or more, particularly Preferably it is 2.0 W / m · K or more.

  The thickness of the insulating sheet 7A can be appropriately selected so as to satisfy the insulating characteristics required between the heat sink 6 and the coil 2. The thickness of the insulating sheet 7A varies depending on the material used for the insulating sheet 7A, but it is sufficient that the thickness is approximately 10 μm or more. Even if the insulating sheet 7A is too thick, there is no meaning. Therefore, the upper limit of the thickness of the insulating sheet 7A is preferably 100 μm. In addition, the thickness of the insulating sheet 7A may be set in consideration of the thermal conductivity of the material used. For example, if the thermal conductivity of the insulating sheet 7A is high (for example, epoxy resin insulating sheet = 0.7 W / m · K), the insulating sheet 7A may be thicker (for example, 100 to 300 μm), but the thermal conductivity is high. If low (for example, polyimide resin insulating sheet = 0.16 W / m · K), the insulating sheet 7A is made thin (for example, 10) within a range in which insulation can be secured between the coil 2 of the reactor 1 and the heat sink 6. ˜50 μm).

  On the other hand, the adhesive sheet 7 </ b> B is required to have insulation characteristics that can sufficiently insulate the coil 2 and the heat radiating plate 6, and heat resistance that does not soften against the maximum temperature when the reactor 1 is used. . For example, a thermosetting resin such as an epoxy resin, a silicone resin, or an unsaturated polyester, or a thermoplastic insulating resin such as a polyphenylene sulfide (PPS) resin or a liquid crystal polymer (LCP) can be suitably used for the adhesive sheet 7B. This insulating resin may contain at least one ceramic filler selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide, so that insulation of the adhesive sheet 7B can be achieved. And heat dissipation can be improved. The thermal conductivity of the adhesive sheet 7B is preferably 0.1 W / m · K or more, more preferably 0.15 W / m · K or more, still more preferably 0.5 W / m · K or more, particularly preferably. 1 W / m · K or more, most preferably 2.0 W / m · K or more.

≪Presser foot member≫
As shown in FIGS. 1 and 2, the pressing member 8 is a member for pressing the first core component 4 </ b> A toward the heat radiating plate 6 to firmly fix the combined body 10 to the heat radiating plate 6. In addition, terminal members 9A and 9B connected to the end portions 2a and 2b of the coil 2 are embedded in the holding member 8, and the holding member 8 includes the coil 2 of the reactor 1 and an external power source (not shown). Also serves as a terminal block for electrical connection with equipment.

  As shown in FIG. 4, the pressing member 8 includes a leg portion 81 as an attachment portion to the heat radiating plate 6 (see FIGS. 1 and 2), and a combined body 10 (see FIGS. 1 and 2) on the upper end side of the leg portion 81. ) And a terminal block 83 that protrudes to the opposite side of the pressing portion 82.

  The leg portion 81 is provided with overhang portions 81A and 81B projecting in the parallel direction of the coil elements 2A and 2B (see FIGS. 1 and 2), and insertion holes 8Ah and 8Bh are formed in the overhang portions 81A and 81B. Has been. As shown in FIG. 2, the bolts which are the fixing members 10A and 10B are inserted into the insertion holes 8Ah and 8Bh, and the fixing members 10A and 10B are screwed to the holding member mounting holes 6Ah and 6Bh of the heat radiating plate 6. The holding member 8 can be fixed to the heat radiating plate 6 (see also FIG. 1). In addition, fixing member 10A, 10B may penetrate the heat sink 6, and may reach the installation object. In that case, the fixed state to the installation object of the reactor 1 can be strengthened more.

  As shown in FIG. 1, the pressing portion 82 abuts against the upper surface of the first core component 4 </ b> A and presses the first core component 4 </ b> A toward the heat sink 6 when the pressing member 8 is fixed to the heat sink 6. . That is, the combined body 10 can be sandwiched between the pressing portion 82 and the heat radiating plate 6, and as a result, the detachment of the combined body 10 from the heat radiating plate 6 is suppressed.

  As shown in FIG. 4, the terminal base 83 serves as a base for connecting the terminal members 9A and 9B connected to the ends 2a and 2b of the coil 2 and the terminal of the lead wire extending from the power source or the like. Part of the terminal members 9A and 9B embedded in the presser member 8 is exposed on the upper surface of the terminal block 83. Further, of the terminal members 9A and 9B, the end opposite to the terminal base portion 83 protrudes from the pressing portion 82 and is bent upward, and the protruding portion is as shown in FIGS. The ends 2a and 2b of the coil 2 are connected to each other. Therefore, if a lead wire is connected to the terminal members 9A and 9B exposed at the terminal block 83, the coil 2 is energized through the terminal members 9A and 9B. A collar having a thread groove is embedded in the lower surface of the exposed portion of the terminal members 9A and 9B in the terminal base 83 so that the terminal of the lead wire and the terminal members 9A and 9B can be screwed. It has become.

  In addition, a partition plate 83F is formed between the terminal members 9A and 9B in the intermediate portion of the terminal block 83 (FIG. 4). The partition plate 83F can ensure insulation between the terminal members 9A and 9B, and can prevent the terminals of the lead wires connected to the terminal members 9A and 9B from contacting and conducting each other.

≪Usage≫
Reactor 1 having the above-described configuration has applications where current-carrying conditions are, for example, maximum current (direct current): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, and usage frequency: about 5 kHz to 100 kHz, typically an electric vehicle. It can be suitably used as a component part of a vehicle-mounted power conversion device such as a hybrid vehicle. In this application, it is expected that an inductance satisfying 10 μH or more and 2 mH or less of the inductance when the DC current is 0 A and 10% or more of the inductance when the maximum current is applied is 10% or more can be suitably used.

≪Effect≫
In the reactor 1 of Embodiment 1 demonstrated above, the operation | work which fits a bobbin in a magnetic core like the conventional structure at the time of the assembly is not required, and only combining the coil 2 and core components 4A and 4B, The combination 10 of the reactor 1 can be completed. Therefore, the reactor 1 is excellent in assembling workability compared with the conventional configuration.

<Modified Embodiment>
In the first embodiment, the bonding layer 7 has a two-layer structure of an insulating sheet 7A and an adhesive sheet 7B (see FIG. 2). On the other hand, it is good also as the reactor 1 provided with the joining layer of single layer structure which consists of insulating resin. This configuration will be described with reference to FIG. 2 which is a reference drawing of the first embodiment.

  In a modified embodiment, a bonding layer 7 is formed with an insulating resin adhesive on a heat sink 6 made of a nonmagnetic metal such as aluminum, and the combined body 10 is placed directly on the bonding layer 7. . By doing so, the combined body 10 and the heat radiating plate 6 can be bonded via the single-layer bonding layer 7. As the material of the bonding layer 7, the same insulating resin as that of the adhesive sheet 7B of Embodiment 1 can be used. Of course, the insulating resin constituting the bonding layer may contain a ceramic filler.

  In the case of a structure in which a single layer of the bonding layer 7 is formed, it is preferable that the formation region of the bonding layer 7 is roughened. By forming the roughened region on the heat sink 6, when the bonding layer 7 is formed on the region, the bonding layer 7 enters the unevenness of the region, and the adhesion between the heat sink 6 and the bonding layer 7 is improved. Increase. Moreover, since the contact area between the heat sink 6 and the bonding layer 7 increases, the heat transfer efficiency between the heat sink 6 and the bonding layer 7 is improved.

  The roughness in the roughened region of the heat sink 6 is preferably 1 μm or more in terms of arithmetic average roughness Ra, and more preferably Ra is 3 μm or more. By doing so, rather than simply forming the bonding layer 7 on the heat sink 6, the adhesion between the heat sink 6 and the bond layer 7 and the heat transfer efficiency can be significantly improved. Here, the upper limit of Ra of the roughened region is preferably 10 μm. This is because if the roughened region is too rough, there is a slight possibility that the bonding layer 7 does not enter the unevenness of the roughened region.

  The roughening treatment method of the heat sink 6 includes (1) anodization represented by anodizing, (2) needle-like plating by a known technique, (3) planting of a molecular bonding compound by a known technique, ( 4) Fine groove processing by laser, (5) Nano-order dimple formation using a known special solution, (6) Etching treatment, (7) Sand blasting and shot blasting, (8) Peeling, (9) Hydroxidation Known methods for improving the adhesion between the metal and the resin, such as matting treatment with sodium and (10) scratching the surface with a metal brush, can be used. In particular, the etching process (6) is preferable.

<Embodiment 2>
The reactor 1 according to the first embodiment can be used for, for example, a component part of a converter mounted on a vehicle or the like, or a component part of a power conversion device including the converter.

  For example, a vehicle 1200 such as a hybrid vehicle or an electric vehicle is used for traveling by being driven by a main battery 1210, a power converter 1100 connected to the main battery 1210, and power supplied from the main battery 1210 as shown in FIG. The motor (load) 1220 is provided. The motor 1220 is typically a three-phase AC motor, which drives the wheel 1250 when traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, vehicle 1200 includes an engine in addition to motor 1220. In addition, in FIG. 5, although an inlet is shown as a charge location of the vehicle 1200, it is good also as a form provided with a plug.

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

  As shown in FIG. 6, the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor L, and converts input voltage by ON / OFF repetition (switching operation). (In this case, step-up / down pressure) is performed. For the switching element 1111, a power device such as FET or IGBT is used. The reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that prevents the change of the current to flow through the circuit. As the reactor L, the reactor 1 described in the above embodiment is used. By using these reactors 1 that are lightweight and easy to handle, the power converter 1100 (including the converter 1110) can be reduced in weight.

  Here, the vehicle 1200 is connected to the converter 1110, the power supply converter 1150 connected to the main battery 1210, and the sub-battery 1230 and the main battery 1210 that are power sources of the auxiliary devices 1240. Auxiliary power supply converter 1160 for converting the high voltage 1210 to a low voltage is provided. The converter 1110 typically performs DC-DC conversion, while the power supply device converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Some power supply device converters 1150 perform DC-DC conversion. The reactors of the power supply device converter 1150 and the auxiliary power supply converter 1160 have the same configuration as the reactors of the above-described embodiments and modifications, and a reactor whose size and shape are appropriately changed can be used. In addition, the reactor of the above-described embodiment can be used for a converter that performs conversion of input power and that only performs step-up or converter that performs only step-down.

  Note that the present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the gist of the present invention.

  The reactor of the present invention can be used as a component of a power conversion device such as a bidirectional DC-DC converter mounted on a vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle.

DESCRIPTION OF SYMBOLS 1 Reactor 10 Combination 2 Coil 2A, 2B Coil element 2a, 2b End part 2r Coil element connection part 3 Magnetic core 31 Inner core part 31m Core piece 31g Gap material 32 Outer core part 4A 1st core component 4B 2nd core component 5A Covering resin 51A Base 510 Mounting portion 511 Cylindrical body 519 Partition portion 52A Peripheral surface covering portion 523 Base covering portion 527 Engaging portion 53A Engaging tube portion 6 Heat radiating plate 61h Core component attaching hole (insertion hole) 6Ah, 6Bh Holding member attaching Hole 7 Bonding layer 7A Insulating sheet 7B Adhesive sheet 8 Holding member 81 Leg part 81A, 81B Overhang part 8Ah, 8Bh Insertion hole 82 Pressing part 83 Terminal block part 83F Partition plate 9A, 9B Terminal member 10A, 10B, 10C Fixing member 1100 Power converter 1110 Converter 1111 Switching element 111 2 Drive Circuit L Reactor 1120 Inverter 1150 Power Supply Converter 1160 Auxiliary Power Supply Converter 1200 Vehicle 1210 Main Battery 1220 Motor 1230 Sub Battery 1240 Auxiliary Equipment 1250 Wheels

Claims (7)

A coil having a pair of coil elements connected in parallel, and an annular magnetic core inserted through the coil elements;
The magnetic core is a reactor having a pair of inner core portions disposed inside the coil element, and a pair of outer core portions that are exposed from the coil element and form a closed magnetic path with the inner core portion,
A pair of core parts in which a set of one inner core part and one outer core part is integrated with a coating resin,
By combining these pair of core parts, each core part provided in both core parts is arranged in an annular shape to form the magnetic core,
The core component includes an attachment portion for attaching the core component to another member,
The mounting portion is
A coating resin constituting the core component;
A cylindrical body that is held by the coating resin and through which a fixing member that fixes the core component to another member is inserted ;
Furthermore, a non-magnetic metal heat radiating plate on which a combination of the coil and the pair of core parts is placed, and an insulating resin disposed between the combination and the heat radiating plate are joined. A bonding layer,
The heat radiating plate includes an insertion hole through which a fixing member for fixing the reactor to the installation target is inserted. The insertion hole overlaps the cylindrical body, and the core component and the heat radiating plate are integrated with the installation target. Reactor configured to be fixed .   The reactor according to claim 1, wherein an arithmetic average roughness Ra of a region where the bonding layer is formed in the heat radiating plate is 1 μm or more.   The reactor according to claim 1, wherein a lower surface of the outer core portion is exposed from the coating resin. The covering resin includes a base portion that covers the outer core portion, a peripheral surface covering portion that protrudes from one surface side of the base portion, a peripheral surface covering portion that covers the peripheral surface of the inner core portion, and a peripheral surface covering portion that protrudes from the one surface side of the base portion. An engagement tube portion in parallel with the portion,
The peripheral surface covering portion includes a base covering portion extending from the base to a predetermined length, and an engaging portion that is continuous with the base covering portion and has an outer diameter smaller than the outer diameter of the base covering portion. ,
When the pair of core parts are combined, the engaging part of one core part fits into the engaging tube part of the other core part, and the engaging part of the other core part is one core part. The reactor according to any one of claims 1 to 3 , wherein the reactor is fitted into the engagement cylinder portion. The reactor according to claim 4 , wherein the base portion includes a partition portion that protrudes from the base portion between the peripheral surface covering portion and the engagement cylinder portion. A converter that includes a switching element, a drive circuit that controls the operation of the switching element, and a reactor that smoothes the switching operation, and converts the input voltage by the operation of the switching element,
The said reactor is a converter which is a reactor of any one of Claims 1-5 . A converter for converting an input voltage, and an inverter connected to the converter and converting between direct current and alternating current, and for driving a load with electric power converted by the inverter,
The said converter is a power converter device which is a converter of Claim 6 .

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