Reactor, Converter and Power Conversion Device

Abstract

A reactor includes an assembly formed by combining a coil, a magnetic core, and a holding member. The holding member has: an outer side surface facing a side of an outer core portion where the magnetic core is disposed; a concave core receiving portion into which a part of the outer core portion is inserted; and a first holding portion facing a first outer peripheral surface of the outer core portion. The first holding portion has: a plate-like piece extending from the outer side surface toward the first outer peripheral surface; and a pressing portion pressing the first outer peripheral surface. The plate-like piece has a first surface flush with an inner wall surface of the core receiving portion, and the pressing portion protrudes toward the first outer peripheral surface compared to the first surface.

Description

Technical Field

[0001] The present disclosure relates to a reactor, a converter, and a power conversion device.

[0002] This application claims priority based on Japanese Patent Application No. 2020-051429 filed on March 23, 2020, and incorporates by reference all of the descriptions recited in the Japanese application. Background Art

[0003] A component of a converter included in a hybrid vehicle or the like has a reactor. For example, the reactor disclosed in Patent Document 1 includes an assembly formed by combining a coil, a magnetic core, and a clamping member. The coil has a winding portion formed by winding a winding into a spiral shape. The magnetic core includes an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding. The clamping member is a holding member that is disposed between the end face of the winding portion and the outer core portion and holds the coil and the magnetic core.

[0004] In the holding member of the reactor of Patent Document 1, a core housing portion is provided as a recess into which a part of the outer core portion is inserted. Further, two flat support pieces are provided on the holding member. Each support piece is flush with the inner wall surface of the core housing portion. The two support pieces sandwich the upper surface and the lower surface of the outer peripheral surface of the outer core portion to determine the position of the outer core portion.

[0005] Prior Art Documents

[0006] Patent Documents

[0007] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2019-153772 Summary of the Invention

[0008] The reactor of the present disclosure includes an assembly formed by combining a coil, a magnetic core, and a holding member.

[0009] The coil includes a winding portion formed by winding a winding.

[0010] The magnetic core includes an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion.

[0011] The holding member is disposed between the end face of the winding portion and the outer core portion.

[0012] Among them,

[0013] The holding member includes:

[0014] An outer side surface facing the side where the outer core portion is disposed;

[0015] A concave core housing portion into which a part of the outer core portion is inserted; and

[0016] The first holding portion faces the first outer peripheral surface of the outer core portion.

[0017] The first holding portion includes:

[0018] a plate-like piece extending from the outer side surface toward the first outer peripheral surface; and

[0019] a pressing portion pressing the first outer peripheral surface.

[0020] The plate-like piece has a first surface flush with the inner wall surface of the core accommodating portion.

[0021] The pressing portion protrudes toward the first outer peripheral surface compared to the first surface.

[0022] The converter of the present disclosure includes the reactor of the present disclosure.

[0023] The power conversion device of the present disclosure includes the converter of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a schematic perspective view of the reactor according to Embodiment 1.

[0025] Figure 2 is from Figure 1 a schematic perspective view of the reactor observed from a different angle.

[0026] Figure 3 is a schematic perspective view of the holding member included in the reactor according to Embodiment 1, observed obliquely from above.

[0027] Figure 4 is a schematic perspective view of the holding member included in the reactor according to Embodiment 1, observed obliquely from below.

[0028] Figure 5 is from Figure 4 the opposite side of

[0029] Figure 6 is Figure 2 a cross-sectional view taken along line VI-VI of

[0030] Figure 7 is a schematic diagram illustrating an example of the manufacturing method of the reactor according to Embodiment 1.

[0031] Figure 8 is a schematic perspective view of the holding member included in the reactor according to Embodiment 2, observed obliquely from above.

[0032] Figure 9 is a schematic perspective view of the holding member included in the reactor according to Embodiment 2, observed obliquely from below.

[0033] Figure 10 is a configuration diagram schematically showing the power supply system of the hybrid vehicle according to Embodiment 3.

[0034] Figure 11 is a schematic circuit diagram showing an example of a power conversion device including the converter according to Embodiment 3. Detailed Embodiment

[0035] [Problems to be Solved by the Present Disclosure]

[0036] A slight gap is provided between the inner wall surface of the core housing portion and the outer peripheral surface of the outer core portion. This gap is a structure for facilitating the insertion of the outer core portion into the core housing portion. However, when the gap between the inner wall surface of the core housing portion and the outer peripheral surface of the outer core portion increases due to dimensional tolerances, the outer core portion may fall down and may come off from the holding member. When the outer core portion comes off, labor and time are required to re-insert the outer core portion, and thus the productivity of the reactor decreases. Therefore, it is desired to improve the productivity of the reactor by providing a reactor that firmly holds the outer core portion in the core housing portion.

[0037] Therefore, one object of the present disclosure is to provide a reactor that firmly holds an outer core portion by a holding member. Moreover, one object of the present disclosure is to provide a converter and a power conversion device including a reactor having excellent productivity.

[0038] [Effects of the Present Disclosure]

[0039] The reactor of the present disclosure can firmly hold the outer core portion to the holding member by the pressing portion provided in the holding member.

[0040] In addition, the converter and the power conversion device of the present disclosure have excellent productivity.

[0041] [Description of Embodiments of the Present Disclosure]

[0042] First, embodiments of the present disclosure will be listed and described.

[0043] <1>The reactor according to the embodiment includes an assembly formed by combining a coil, a magnetic core, and a holding member.

[0044] The coil includes a winding portion formed by winding a winding.

[0045] The magnetic core includes an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion.

[0046] The holding member is disposed between the end face of the winding portion and the outer core portion.

[0047] Among them,

[0048] The holding member includes:

[0049] An outer side surface facing the side where the outer core portion is disposed;

[0050] A concave core accommodating portion into which a part of the outer core portion is inserted; and

[0051] A first holding portion facing the first outer peripheral surface of the outer core portion,

[0052] The first holding portion includes:

[0053] A plate-like piece extending from the outer side surface toward the first outer peripheral surface; and

[0054] A pressing portion pressing the first outer peripheral surface,

[0055] The plate-like piece has a first surface flush with the inner wall surface of the core accommodating portion,

[0056] The pressing portion protrudes toward the first outer peripheral surface compared to the first surface.

[0057] Here, the first outer peripheral surface is one of a plurality of outer peripheral surfaces. The plurality of outer peripheral surfaces are the surfaces of the outer core portion other than the inner end surface and the outer end surface. The inner end surface is the surface of the outer core portion facing the end surface of the inner core portion. The outer end surface is the surface facing the direction away from the end surface of the inner core portion. The first outer peripheral surface is, for example, the upper surface, the lower surface, or the side surface of the outer core portion.

[0058] In the reactor of the present disclosure, the outer core portion is firmly held by the holding member.

[0059] In the reactor of the present disclosure, the pressing portion included in the holding member protrudes toward the first outer peripheral surface of the outer core portion compared to the first surface of the plate-like piece. Since the first surface is flush with the inner wall surface of the core accommodating portion, the pressing portion of the holding member protrudes toward the first outer peripheral surface of the outer core portion compared to the inner wall surface of the core accommodating portion. By pressing the first outer peripheral surface of the outer core portion with this pressing portion, the outer core portion is pressed against the portion of the inner wall surface of the core accommodating portion on the side opposite to the pressing portion. Therefore, even if the gap between the inner wall surface of the core accommodating portion and the outer peripheral surface of the outer core portion increases due to the dimensional tolerance between the holding member and the outer core portion, the outer core portion can be firmly held by the holding member by the pressing portion. As a result, the detachment of the outer core portion from the holding member can be suppressed. Therefore, the labor and time for reinserting the outer core portion into the core accommodating portion of the holding member are reduced, and thus the productivity of the reactor is improved.

[0060] <2>As one mode of the reactor of the embodiment, the following mode can be cited:

[0061] The pressing portion is a protrusion provided on the first surface,

[0062] The rib extends in the depth direction of the core housing portion.

[0063] The rib provided on the first surface of the plate-like piece can firmly press the first outer peripheral surface of the outer core portion. Moreover, when the rib presses the first outer peripheral surface of the outer core portion, the plate-like piece flexes, so that an excessive pressing force is difficult to act on the first outer peripheral surface of the outer core portion.

[0064] <3>As one mode of the reactor of <2> above, the following mode can be cited:

[0065] The protruding amount of the rib protruding from the first surface increases as it approaches the bottom surface of the core housing portion.

[0066] In other words, the above structure is a structure in which the protruding amount of the rib decreases as it goes from the bottom surface of the core housing portion toward the opening portion. When the protruding amount of the rib decreases as it goes from the bottom surface of the core housing portion toward the opening portion, the outer core portion is easily inserted into the core housing portion. Moreover, if the protruding amount of the rib increases as it approaches the bottom surface of the core housing portion, the force with which the rib presses the outer core portion increases as the outer core portion is pressed into the bottom of the core housing portion. Therefore, the outer core portion embedded deep in the core housing portion is difficult to fall off from the core housing portion.

[0067] <4>As one mode of the reactor of <2> or <3> above, the following mode can be cited:

[0068] The cross-sectional shape of the rib orthogonal to the extending direction is a tapered shape that narrows as it approaches the protruding direction of the rib.

[0069] When the outer core portion is inserted into the core housing portion, the contact area between the rib and the outer core portion decreases due to the tip of the rib becoming thinner. Therefore, the outer core portion is easily inserted into the core housing portion.

[0070] <5>As one mode of the reactor of <1> above, the following mode can be cited:

[0071] The pressing portion is a cantilever spring.

[0072] When the outer core portion is inserted into the core housing portion, the pressing portion formed of the cantilever spring flexes in a direction separating from the first outer peripheral surface of the outer core portion. Therefore, the cantilever spring is difficult to damage the first outer peripheral surface of the outer core portion. Moreover, the cantilever spring presses the first outer peripheral surface of the outer core portion by its elasticity and firmly holds the outer core portion in the core housing portion.

[0073] <6>As one mode of the reactor of <5> above, the following mode can be cited:

[0074] The cantilever spring is provided on the side of the plate-like piece.

[0075] The cantilever spring provided on the side of the plate-like piece is independent of the plate-like piece. The formation of the cantilever spring independent of the plate-like piece is easier than the formation of the cantilever spring provided on the first surface of the plate-like piece.

[0076] <7>As one mode of the reactor of the above <5> or <6>, the following mode can be cited:

[0077] The root of the cantilever spring is connected to the inner wall surface of the core housing portion.

[0078] The inner wall surface of the core housing portion is higher in rigidity and less likely to deform than the plate-like piece. Therefore, if the root of the cantilever spring is connected to the inner wall surface of the core housing portion, it is easy to appropriately ensure the pressing force generated by the cantilever spring. In contrast, if the root of the cantilever spring is connected to the plate-like piece, the plate-like piece may also flex corresponding to the flexure of the cantilever spring. Therefore, the pressing force generated by the cantilever spring may be unstable.

[0079] <8>As one mode of the reactor of the embodiment, the following mode can be cited:

[0080] The holding member has a through hole penetrating the inner core portion.

[0081] When the holding member is viewed from the front in the direction of the outer side surface, the pressing portion is provided at a position overlapping the through hole.

[0082] The holding member is usually resin-molded. Here, if the pressing portion is provided at a position overlapping the through hole, the mold release property of the molding die corresponding to the pressing portion is improved.

[0083] <9>As one mode of the reactor of the embodiment, the following mode can be cited:

[0084] The holding member has a second holding portion extending along the axial direction of the winding portion from the outer side surface.

[0085] The second holding portion is provided at a position facing the first holding portion with the core housing portion interposed therebetween.

[0086] In a reactor in which there is a second holding portion in addition to the first holding portion, the outer core portion is sandwiched between the first holding portion and the second holding portion at a position outside the core housing portion. Therefore, the outer core portion is difficult to fall off from the core housing portion of the holding member.

[0087] <10>As one mode of the reactor of the embodiment, the following mode can be cited:

[0088] The reactor has an outer molding portion covering at least a part of the outer periphery of the combination.

[0089] Through the outer molding part, each structural member of the assembly is firmly integrated. In particular, if the outer core part is integrated with the holding member through the outer molding part, it is difficult to disassemble each structural member of the assembly. Moreover, the outer core part can be protected from the influence of the external environment through the outer molding part.

[0090] <11>As one mode of the reactor of the embodiment, it includes any one of the reactors in <1> to <10> above.

[0091] The converter of the present disclosure includes the reactor of the present disclosure with excellent productivity. Therefore, the converter of the present disclosure is excellent in productivity.

[0092] <12>The power conversion device of the embodiment includes the converter of <11> above.

[0093] The power conversion device of the present disclosure includes the converter of the present disclosure with excellent productivity. Therefore, the power conversion device of the present disclosure is excellent in productivity.

[0094] [Details of the embodiment of the present disclosure]

[0095] Hereinafter, based on the drawings, an embodiment of the reactor of the present disclosure will be described. The same reference numerals in the drawings denote the same objects. It should be noted that the present invention is not limited to the structure shown in the embodiment, is disclosed by the claims, and is intended to include all changes within the meaning equivalent to the claims and the scope.

[0096] <Embodiment 1>

[0097] In Embodiment 1, based on Figures 1 to 7 , the structure of the reactor 1 will be described. Figure 1 , 2 The reactor 1 shown in includes an assembly 10 formed by combining a coil 2, a magnetic core 3, and a holding member 4. As one of the features of the reactor 1, the structure of the holding member 4 can be cited. Hereinafter, each structure included in the reactor 1 will be described in detail.

[0098] 《Coil》

[0099] The coil 2 in this example includes winding parts 21 and 22 arranged side by side with each other, and a connecting part 23 connecting the two winding parts 21 and 22. Each of the winding parts 21 and 22 is formed by winding a single winding. The winding can use a known winding. The winding in this example is a covered flat wire. The conductor wire of the covered flat wire is composed of a copper flat wire. The insulating coating of the covered flat wire is composed of enamel paint. The winding parts 21 and 22 are formed by flatly winding the covered flat wire into flat coils.

[0100] The shapes of the winding portions 21 and 22 are rectangular tubular shapes. A rectangle includes a square. That is, the end face shapes of the winding portions 21 and 22 are rectangular frame shapes. Since the shapes of the winding portions 21 and 22 are rectangular tubular shapes, it is easier to increase the contact area between the winding portions 21 and 22 and the installation object compared to the case where the winding portion has a cylindrical shape with the same cross-sectional area. Therefore, the reactor 1 can easily dissipate heat to the installation object through the winding portions 21 and 22. Moreover, the winding portions 21 and 22 can be easily and stably installed on the installation object. The corners of the winding portions 21 and 22 are preferably rounded.

[0101] The end portions 2a and 2b of the coil 2 extend to the outer peripheral sides of the winding portions 21 and 22, respectively. At the end portions 2a and 2b, the insulating coating is peeled off and the conductor wires are exposed. The exposed conductor wires are connected to terminal members (not shown). The coil 2 is connected to an external device via the terminal members. The illustration of the external device is omitted. Examples of the external device include a power supply that supplies power to the coil 2.

[0102] Here, the directions in the reactor 1 are defined based on the coil 2. First, the direction along the axial direction of the winding portions 21 and 22 of the coil 2 is defined as the X-axis direction. The direction orthogonal to the X-axis direction and along the juxtaposed direction of the winding portions 21 and 22 is defined as the Y-axis direction. And the direction intersecting both the X-axis direction and the Y-axis direction is defined as the Z-axis direction. In addition, the following directions are defined.

[0103] · The X1 direction... The direction in the X-axis direction toward the end portions 2a and 2b

[0104] · The X2 direction... The direction in the X-axis direction toward the connecting portion 23

[0105] · The Y1 direction... The direction in the Y-axis direction toward the winding portion 21

[0106] · The Y2 direction... The direction in the Y-axis direction toward the winding portion 22

[0107] · The Z1 direction... The direction in the Z-axis direction toward the side where the connecting portion 23 is disposed

[0108] · The Z2 direction... The direction in the Z-axis direction opposite to the Z1 direction

[0109] 《Magnetic Core》

[0110] The magnetic core 3 includes an inner core portion 31, an inner core portion 32, an outer core portion 33, and an outer core portion 34. The inner core portion 31 is disposed inside the winding portion 21. The inner core portion 32 is disposed inside the winding portion 22. The outer core portion 33 connects the end portion of the inner core portion 31 in the X1 direction to the end portion of the inner core portion 32. The outer core portion 34 connects the end portion of the inner core portion 31 in the X2 direction to the end portion of the inner core portion 32. By connecting these core portions 31, 32, 33, and 34 in a ring shape, a closed magnetic circuit is formed.

[0111] [Inner core part]

[0112] The inner core parts 31 and 32 are parts along the axial direction of the winding parts 21 and 22 of the coil 2, that is, in the X-axis direction. In this example, both ends of the part of the magnetic core 3 along the axial direction of the winding parts 21 and 22 protrude from the end faces of the winding parts 21 and 22. The above-mentioned protruding parts are also part of the inner core parts 31 and 32.

[0113] The shape of the inner core parts 31 and 32 only needs to be a shape along the inner peripheral shape of the winding parts 21 and 22, and there is no particular limitation. The inner core parts 31 and 32 in this example are substantially rectangular parallelepiped-shaped. The inner core parts 31 and 32 can be configured as a structure connecting a plurality of divided cores and spacer plates, or can be configured as a single member.

[0114] [Outer core part]

[0115] The outer core parts 33 and 34 are parts of the magnetic core 3 arranged outside the winding parts 21 and 22. The shape of the outer core parts 33 and 34 only needs to be a shape connecting the ends of a pair of inner core parts 31 and 32, and there is no particular limitation. The outer core parts 33 and 34 in this example are columnar bodies with substantially dome-shaped upper and lower surfaces.

[0116] The outer core parts 33 and 34 have inner end faces 3a( Figure 6 ), outer end faces 3b, and first outer peripheral faces 3c. The inner end faces 3a( Figure 6 ) are the faces facing the end faces of the inner core parts 31 and 32 in the X-axis direction. The outer end faces 3b are the faces facing the direction away from the end faces of the inner core parts 31 and 32 in the X-axis direction. The first outer peripheral face 3c in this example is the upper surface facing the Z1 direction. In the outer core parts 33 and 34 of this example, in addition to the first outer peripheral face 3c, there are also a lower surface facing the Z2 direction, that is, a second outer peripheral face 3d( Figure 6 ), a side face facing the Y1 direction, that is, a third outer peripheral face 3e, a side face facing the Y2 direction, that is, a fourth outer peripheral face 3f, etc. Different from this example, the lower surface or side face of the outer core parts 33 and 34 can also be defined as the first outer peripheral face. For example, when the lower surface of the outer core parts 33 and 34 is set as the first outer peripheral face, the first holding part 5( Figure 6 ) described later is arranged at a position facing the lower surface of the outer core parts 33 and 34.

[0117] As Figure 1 shown, at least a part of the outer core part 33 in this example is covered by the core molding part 7. The structure of the core molding part 7 will be described later.

[0118] [Magnetic characteristics / materials, etc.]

[0119] Each of the core portions 31, 32, 33, and 34 of the magnetic core 3 is preferably a compacted powder compact formed by compacting a raw material powder containing soft magnetic powder, or a formed body of a composite material of soft magnetic powder and resin. All of the core portions 31, 32, 33, and 34 may be compacted powder compacts, or all of the core portions 31, 32, 33, and 34 may be formed bodies of composite materials. Moreover, part of the core portions 31, 32, 33, and 34 may be compacted powder compacts and the rest may be formed bodies of composite materials. The magnetic core 3 in which part is a compacted powder compact and the rest is a formed body of composite material is difficult to be magnetically saturated.

[0120] The soft magnetic powder of the compacted powder compact is an aggregate of soft magnetic particles composed of iron group metals such as iron, or iron alloys such as Fe (iron)-Si (silicon) alloy and Fe-Ni (nickel) alloy. An insulating coating composed of phosphate or the like may also be formed on the surface of the soft magnetic particles. The raw material powder may also contain a lubricating material or the like.

[0121] The formed body of the composite material can be manufactured by filling a mixture of soft magnetic powder and uncured resin into a mold and curing the resin. The soft magnetic powder of the composite material can be the same powder as the powder that can be used in the compacted powder compact. On the other hand, examples of the resin contained in the composite material include thermosetting resins, thermoplastic resins, room temperature curable resins, and low temperature curable resins. Examples of the thermosetting resin include unsaturated polyester resins, epoxy resins, polyurethane resins, and silicone resins. Examples of the thermoplastic resin include polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resins such as nylon 6 or nylon 66, polybutylene terephthalate (PBT) resin, acrylonitrile-butadiene-styrene (ABS) resin, etc. In addition, BMC (Bulk molding compound) in which calcium carbonate and glass fiber are mixed in unsaturated polyester, kneaded silicone rubber, kneaded polyurethane rubber, etc. can also be used.

[0122] When the above-mentioned composite material contains a filler of non-magnetic and non-metallic powder such as alumina and silica in addition to the soft magnetic powder and resin, the heat dissipation performance can be further improved. The content of the non-magnetic and non-metallic powder may be 0.2% by mass or more and 20% by mass or less, further 0.3% by mass or more and 15% by mass or less, 0.5% by mass or more and 10% by mass or less.

[0123] The content of the soft magnetic powder in the composite material can be, for example, 30% by volume or more and 80% by volume or less. From the viewpoints of improving the saturation magnetic flux density and heat dissipation, the content of the soft magnetic powder can further be set to 50% by volume or more, 60% by volume or more, or 70% by volume or more. From the viewpoint of improving the fluidity during the manufacturing process, it is preferable to set the content of the soft magnetic powder to 75% by volume or less. In the formed body of the composite material, if the filling rate of the soft magnetic powder is adjusted to be low, its relative magnetic permeability is likely to decrease. The relative magnetic permeability of the formed body of the composite material is, for example, 5 or more and 50 or less. The relative magnetic permeability of the formed body of the composite material can also be 10 or more and 45 or less, 15 or more and 40 or less, or 20 or more and 35 or less.

[0124] The content of the soft magnetic powder in the compacted powder formed body can be more easily increased compared to that in the formed body of the composite material. For example, the content of the soft magnetic powder in the compacted powder formed body exceeds 80% by volume, and further is 85% by volume or more. The magnetic core block composed of the compacted powder formed body is likely to be a magnetic core block having a high saturation magnetic flux density and relative magnetic permeability. The relative magnetic permeability of the compacted powder formed body is, for example, 50 or more and 500 or less. The relative magnetic permeability of the compacted powder formed body can also be 80 or more, 100 or more, 150 or more, or 180 or more.

[0125] Retention member

[0126] Figure 2 The retention member 4 shown is interposed between the end faces in the X2 direction of the winding portions 21 and 22 of the coil 2 and the inner end face 3a ( Figure 6 ) of the outer core portion 34 of the magnetic core 3 and retains the coil 2 and the magnetic core 3. The retention member 4 is typically made of an insulating material and functions as an insulating member between the coil 2 and the magnetic core 3. Moreover, the retention member 4 also functions as a positioning member for the inner core portions 31 and 32 and the outer core portions 33 and 34 of the winding portions 21 and 22.

[0127] As Figures 3 to 5 shown, the retention member 4 includes a core housing portion 40, a through hole 41, a coil housing portion 42, a core support portion 43, a protruding portion 44, an anti-disengagement portion 45, a first retention portion 5, and a second retention portion 6.

[0128] [Core housing portion]

[0129] As Figure 3 , 4 shown, the core housing portion 40 is provided on the outer side face 4b of the retention member 4 facing the outer core portion 34 ( Figure 6 ). The core housing portion 40 is formed by a depression on the outer side face 4b of the retention member 4. A part of the outer core portion 34 is inserted into the core housing portion 40. A part of the outer core portion 34 is the inner end face 3a and its vicinity ( Figure 6)。The core storage portion 40 has a bottom surface 40b facing the X2 direction and an inner wall surface 40s from the bottom surface 40b to the opening of the core storage portion 40. The inner end surface 3a of the outer core portion 34 is close to or in contact with the bottom surface 40b( Figure 6 )。

[0130] When the core storage portion 40 is viewed from the front in the direction of the outer end surface 3b of the outer core portion 34, it has a shape that generally follows the contour line of the outer core portion 34. However, a part of the upper edge portion and a part of the side edge portion of the core storage portion 40 extend outward beyond the above-mentioned contour line. The portions other than the outwardly extending portions follow the contour line of the outer core portion 34, so the movement of the outer core portion 34 inserted into the core storage portion 40 in the Y-axis direction and the Z-axis direction is restricted.

[0131] [Through-hole]

[0132] The through-hole 41 is a hole that penetrates the holding member 4 in the thickness direction. The through-hole 41 penetrates the bottom surface 40b of the core storage portion 40. The end portion of the inner core portion 31( Figure 1 、 2 ) is disposed in one through-hole 41, and the end portion of the inner core portion 32( Figure 1 、 2 ) is disposed in the other through-hole 41.

[0133] [Coil storage portion]

[0134] As Figure 5 shown, the coil storage portion 42 is provided on the inner side surface 4a of the holding member 4 facing the inner core portions 31, 32( Figure 1 、 2 ). The coil storage portion 42 is a recess formed so as to surround the through-hole 41. Moreover, the shape of the recess follows the end surface shape of the winding portions 21, 22( Figure 1 、 2 ). Therefore, the end surfaces of the winding portions 21, 22 are in surface contact with the holding member 4 at the position of the coil storage portion 42.

[0135] [Core support portion]

[0136] As Figures 3 to 5 shown, the core support portion 43 extends radially inward from the inner peripheral surface of each through-hole 41 to support the corner portions of the inner core portions 31, 32. The core support portion 43 in this example is an arc-shaped piece along the rounded corners of the outer peripheral surfaces of the inner core portions 31, 32. One core support portion 43 is provided at each of the four corners of each through-hole 41. Moreover, the four core support portions 43 respectively support the winding portions 21, 22( Figure 1 、 2Four corners of the inner peripheral surface of ( ). As a result, the relative positions of the winding portions 21 and 22 and the inner core portions 31 and 32 are determined by the core support portion 43. A gap corresponding to the thickness of the core support portion 43 is formed between the inner peripheral surface of the winding portions 21 and 22 and the outer peripheral surface of the inner core portions 31 and 32.

[0137] The upper edge portion, lower edge portion, and both side edge portions of each through hole 41 except for the core support portion 43 extend outward from the contour line of the end surface of the inner core portions 31 and 32. Therefore, the shape of the through hole 41 observed from the axial direction of the through hole 41 becomes substantially a "+" shape. If the inner core portions 31 and 32 are inserted into the through hole 41, a resin filling hole that penetrates in the thickness direction of the holding member 4 is formed between the outer peripheral surface of the inner core portions 31 and 32 inserted into the through hole 41 and the inner peripheral surface of the through hole 41. The resin filling hole communicates with the gap between the winding portions 21 and 22 inside the winding portions 21 and 22 and the inner core portions 31 and 32.

[0138] [Protrusion portion]

[0139] The protrusion portion 44 protrudes inward from the inner wall surface 40s of the core housing portion 40 and determines the position of the outer core portion 34 in the Y-axis direction. The protrusion portion 44 of this example also extends to the inner peripheral surface of the through hole 41 and the inner peripheral surface of the anti-disengagement portion 45. The protrusion portion 44 may not be provided.

[0140] [Anti-disengagement portion]

[0141] As Figure 3 , 4 shown, the anti-disengagement portion 45 is a protrusion provided along the side edge of the core housing portion 40 on the outer side surface 4b. The front end of the anti-disengagement portion 45 on the left side of the paper surface in the X2 direction bends toward the Y2 direction side separated from the core housing portion 40. Moreover, the front end of the anti-disengagement portion 45 on the right side of the paper surface in the X2 direction bends toward the Y1 direction side separated from the core housing portion 40. That is, the cross section of the anti-disengagement portion 45 orthogonal to the Z-axis direction is substantially L-shaped. The anti-disengagement portion 45 suppresses the case where the outer molding portion 8 ( Figure 7 ) that covers the outer periphery of the outer core portion 34 is peeled off from the holding member 4. Regarding the outer molding portion 8, refer to Figure 7 , which will be described later.

[0142] [First holding portion]

[0143] As Figure 4 shown, the first holding portion 5 includes a plate-like piece 50 and a pressing portion 51. The plate-like piece 50 of this example is provided on the outer side surface 4b of the holding member 4 and extends along the X2 direction in which the outer core portion 34 is disposed. The plate-like piece 50 is provided along the upper edge of the opening of the core housing portion 40. The first surface 50s of the plate-like piece 50 facing the Z2 direction is flush with the inner wall surface 40s of the core housing portion 40. In Figure 4In [the figure], the boundary between the first surface 50s and the inner wall surface 40s is indicated by a double-dashed line. As Figure 6 shown, the first surface 50s holds the first outer peripheral surface 3c of the outer core portion 34 along the first outer peripheral surface 3c of the outer core portion 34.

[0144] In this example, the pressing portion 51 is a protrusion provided on the first surface 50s of the plate-like piece 50 and extending along the depth direction of the core accommodating portion 40, i.e., the X-axis direction. Therefore, the pressing portion 51 protrudes more toward the first outer peripheral surface 3c of the outer core portion 34 than the first surface 50s. As Figure 6 shown, the first surface 50s is flush with the inner wall surface 40s of the core accommodating portion 40. Therefore, the pressing portion 51 protrudes more toward the first outer peripheral surface 3c than the inner wall surface 40s. Therefore, even if the gap between the inner wall surface 40s of the core accommodating portion 40 and the first outer peripheral surface 3c of the outer core portion 34 increases due to the dimensional tolerance between the holding member 4 and the outer core portion 34, the outer core portion 34 can be firmly held by the holding member 4 through the pressing portion 51. Moreover, by providing the pressing portion 51 on the plate-like piece 50, when the pressing portion 51 presses the first outer peripheral surface 3c of the outer core portion 34, the plate-like piece 50 flexes. As a result, it is possible to suppress a situation where an excessive pressing force acts on the first outer peripheral surface 3c of the outer core portion 34. Therefore, the first outer peripheral surface 3c is less likely to be damaged by the pressing portion 51.

[0145] As Figure 4 shown, the number of the pressing portions 51 in this example is two. When the holding member 4 is viewed frontally from the outer side surface 4b side, the two pressing portions 51 are provided at positions overlapping the through-hole 41. If the pressing portion 51 is at a position corresponding to the through-hole 41, the forming die corresponding to the pressing portion 51 can be pulled out toward the through-hole 41 side. Therefore, the demolding property of the forming die is improved. Here, the number of the pressing portions 51 can also be one, or three or more.

[0146] The cross-sectional shape of the pressing portion 51 orthogonal to the extending direction is preferably a tapered shape that narrows as it goes toward the protruding direction of the pressing portion 51. The cross-sectional shape of the pressing portion 51 in this example is triangular ( Figure 4 ). By tapering the tip of the pressing portion 51, when the outer core portion 34 is inserted into the core accommodating portion 40, the contact area between the pressing portion 51 and the outer core portion 34 decreases. Therefore, it is easy to insert the outer core portion 34 into the core accommodating portion 40. Moreover, if the tip of the pressing portion 51 is a tapered shape, the pressing portion 51 is easily flattened, and there is also an effect that the first outer peripheral surface 3c is less likely to be damaged by the pressing portion 51. Here, different from this example, as the tapered cross-sectional shape of the pressing portion 51, a trapezoid or a semicircle can be cited. Of course, the cross-sectional shape of the pressing portion 51 is not limited to a tapered shape, and it can also be, for example, a rectangle.

[0147] In addition, the protruding amount of the pressing portion 51 protruding from the first surface 50s may be uniform in the longitudinal direction of the pressing portion 51, but it is preferably increased as it approaches the bottom surface 40b of the core accommodating portion 40. In other words, the protruding amount of the pressing portion 51 protruding from the first surface 50s is preferably decreased as it approaches the opening portion from the bottom surface 40b of the core accommodating portion 40. When the protruding amount of the pressing portion 51 is decreased as it approaches the opening portion of the core accommodating portion 40, the outer core portion 34 is easily inserted into the core accommodating portion 40. Further, if the protruding amount of the pressing portion 51 is increased as it approaches the bottom surface 40b of the core accommodating portion 40, the force with which the pressing portion 51 presses the outer core portion 34 increases as the outer core portion 34 is pressed into the core accommodating portion 40 toward the bottom surface 40b. Therefore, the outer core portion 34 inserted deep into the core accommodating portion 40 is difficult to fall off from the core accommodating portion 40.

[0148] As another form of the pressing portion 51, the pressing portion 51 may be provided on the inner wall surface 40s of the core accommodating portion 40. In this case, the pressing portion 51 also protrudes more toward the first outer peripheral surface 3c of the outer core portion 34 than the first surface 50s. Of course, the pressing portion 51 may be provided from the first surface 50s to the inner wall surface 40s.

[0149] [Second Holding Portion]

[0150] As shown in Figure 3 and 4 and 6, the second holding portion 6 includes a plate-like piece 60. The plate-like piece 60 of this example is provided on the outer side surface 4b of the holding member 4 and extends along the X2 direction in which the outer core portion 34 is arranged. The plate-like piece 60 is provided along the lower edge of the opening portion of the core accommodating portion 40. As shown in Figure 3 , the second surface 60s, which is the upper surface of the plate-like piece 60, is flush with the inner wall surface 40s of the core accommodating portion 40. In Figure 3 , the boundary between the second surface 60s and the inner wall surface 40s is indicated by a double-dot chain line. As shown in Figure 6 , the second surface 60s holds the second outer peripheral surface 3d, which is the lower surface of the outer core portion 34, along the second outer peripheral surface 3d.

[0151] By sandwiching the outer core portion 34 with the first holding portion 5 and the second holding portion 6, it is easy to prevent the outer core portion 34 from falling off the holding member 4.

[0152] Here, different from this example, the second holding portion 6 may also include a pressing portion in the same manner as the first holding portion 5. In this case, the pressing portion of the second holding portion 6 is configured to protrude toward the second outer peripheral surface 3d of the outer core portion 34 more than the second surface 60s of the plate-like piece 60.

[0153] [Material]

[0154] The holding member 4 can be made of a thermoplastic resin such as PPS resin, PTFE resin, LCP, PA resin, PBT resin, ABS resin, etc. In addition, the holding member 4 can be made of a thermosetting resin such as unsaturated polyester resin, epoxy resin, polyurethane resin, silicone resin, etc. These resins can also contain ceramic fillers to improve the heat dissipation of the holding member 4. As the ceramic filler, for example, non-magnetic powders such as alumina and silica can be used.

[0155] 《Mandrel Molding Part》

[0156] As Figure 1 shown, the mandrel molding part 7 covers at least a part of the outer periphery of the outer core part 33. In this example, the mandrel molding part 7 includes a clamping part 70, a holding part 71, and an anti-disengagement part 75. The clamping part 70 has the same function as the holding member 4. That is, the mandrel molding part 7 has a part that is clamped between the end faces of the winding parts 21 and 22 and the inner end face 3a of the outer core part 33 to hold the coil 2 and the magnetic core 3. At the end face in the X1 direction in the clamping part 70, there are parts corresponding to the coil accommodation part 42 and the core support part 43 in the holding member 4.

[0157] The holding part 71 of the mandrel molding part 7 is a strip-shaped member arranged on the outer peripheral surface 3e, the outer end face 3b, and the outer peripheral surface 3f on the X1 direction side of the outer core part 33. The width of the holding part 71 in the Z-axis direction is shorter than the height of the outer core part 33.

[0158] The anti-disengagement part 75 has the same structure as the anti-disengagement part 45 of the holding member 4. That is, the anti-disengagement part 75 inhibits the peeling of the outer molding part 8 ( Figure 7 ) that covers the outer periphery of the outer core part 33 from the mandrel molding part 7.

[0159] The mandrel molding part 7 is made of, for example, the thermoplastic resin or thermosetting resin described in the items of the holding member 4. The mandrel molding part 7 can also contain ceramic fillers.

[0160] Here, different from this example, the outer core part 33 can also be configured to be held by the holding member 4.

[0161] 《Others》

[0162] Figure 1 , 2 The reactor 1 can also be provided with an outer molding part 8 that covers at least a part of the outer periphery of the assembly 10 (see Figure 7)。The respective structural members of the assembly 10 are firmly integrated by the outer molding portion 8. The outer molding portion 8 may cover the entire outer periphery of the assembly 10, or may cover a part of the outer periphery of the assembly 10 except for the coil 2. In the latter structure, since the coil 2 is exposed to the outside, the heat dissipation performance of the reactor 1 is improved. Further, the outer core portions 33 and 34 are protected from the influence of the external environment by the outer molding portion 8.

[0163] <Effect>

[0164] In the reactor 1 according to the present example, even when the axial directions of the winding portions 21 and 22 are arranged along the horizontal plane, it is difficult for the outer core portion 34 to come off from the holding member 4. This is because the pressing portion 51 provided on the holding member 4 presses the first outer peripheral surface 3c which is the upper surface of the outer core portion 34, thereby firmly holding the outer core portion 34 in the core housing portion 40.

[0165] <Method for manufacturing a reactor>

[0166] Based on Figure 7 , an example of a method for manufacturing the reactor 1 according to Embodiment 1 will be described.

[0167] As Figure 7 shown in the upper diagram of, in the manufacturing method of the present example, the outer core portions 33 and the coil 2 covered by the core molding portion 7 are sequentially stacked from vertically below. Next, the inner core portions 31 and 32 ( Figure 1 , 2 ) are inserted into the winding portions 21 and 22 of the coil 2, and the holding member 4 is stacked at the ends of the winding portions 21 and 22. Finally, the outer core portion 34 is inserted into the core housing portion 40 of the holding member 4 from above. According to the manufacturing method of the present example in which the respective members are sequentially stacked from vertically below, it is easy to manufacture the assembly 10 of the reactor 1.

[0168] Next, as Figure 7 shown in the lower diagram of, the assembly 10 is placed horizontally. Specifically, the assembly 10 is arranged such that the axial direction of the winding portion 21 is along the horizontal plane. At this time, the outer core portion 34 is held by the pressing portion 51 in the holding member 4, and the outer core portion 34 does not come off from the holding member 4. In this state, the outer molding portion 8 is formed on the outer peripheries of the outer core portions 33 and 34. As a result, the outer core portion 33 is integrated with the core molding portion 7 by the outer molding portion 8, and the outer core portion 34 is integrated with the holding member 4 by the outer molding portion 8. The outer molding portion 8 covering the outer core portion 33 and the outer molding portion 8 covering the outer core portion 34 are connected inside the winding portions 21 and 22.

[0169] <Embodiment 2>

[0170] Based on Figure 8 ,9 , the reactor 1 of Embodiment 2 is described. The difference between the reactor 1 in this example and the reactor 1 in Embodiment 1 lies only in the structure of the holding member 4. Therefore, in this example, only the holding member 4 is described.

[0171] As Figure 8 , 9 shown, the first holding portion 5 of the holding member 4 in this example includes two pressing portions 52, 52 provided at positions where the plate-like piece 50 is sandwiched. The pressing portion 52 in this example is in the shape of a cantilever spring. As Figure 9 shown, the root of the pressing portion 52 is connected to the inner wall surface 40s of the core accommodating portion 40. The front end of the pressing portion 52 extends in the X2 direction.

[0172] When the outer core portion 34 ( Figure 2 ) is inserted into the core accommodating portion 40, the pressing portion 52 formed of a cantilever spring deflects in a direction away from the first outer peripheral surface 3c of the outer core portion 34. Therefore, the pressing portion 52 of the cantilever spring hardly damages the first outer peripheral surface 3c of the outer core portion 34. Moreover, the pressing portion 52 of the cantilever spring presses the first outer peripheral surface 3c of the outer core portion 34 by its elasticity, and firmly holds the outer core portion 34 in the core accommodating portion 40.

[0173] The pressing portion 52 of the cantilever spring provided on the side of the plate-like piece 50 is independent of the plate-like piece 50. The formation of the pressing portion 52 of the cantilever spring independent of the plate-like piece 50 is easier than the formation of the pressing portion of the cantilever spring integrally provided on the first surface 50s of the plate-like piece 50.

[0174] The inner wall surface 40s of the core accommodating portion 40 has higher rigidity and is less likely to deform than the plate-like piece 50. Therefore, if the root of the pressing portion 52 of the cantilever spring is connected to the inner wall surface 40s of the core accommodating portion 40, it is easy to appropriately ensure the pressing force generated by the pressing portion 52 of the cantilever spring. Different from this example, if the root of the pressing portion 52 of the cantilever spring is connected to the plate-like piece 50, the plate-like piece 50 may also deflect according to the deflection of the pressing portion 52 of the cantilever spring, and the pressing force generated by the pressing portion 52 may be unstable.

[0175] As the pressing portion 52 of the cantilever spring different from this example, it may also be a pressing portion 52 whose front end extends in the X1 direction. In this case, the root of the pressing portion 52 is provided on the first surface 50s of the plate-like piece 50. Moreover, the number of the pressing portions 52 may also be one, or may be three or more.

[0176] <Embodiment 3>

[0177] <Converter / Power Conversion Device>

[0178] The reactors 1 of Embodiments 1 and 2 can be used for applications that meet the following energization conditions. As the energization conditions, for example, it can be cited that the maximum DC current is about 100 A or more and 1000 A or less, the average voltage is about 100 V or more and 1000 V or less, and the operating frequency is about 5 kHz or more and 100 kHz or less. The reactors 1 of Embodiments 1 and 2 can typically be used as components of a converter mounted on vehicles such as electric vehicles and hybrid vehicles, and components of a power conversion device having such a converter.

[0179] As Figure 10 shown, vehicles 1200 such as hybrid vehicles and electric vehicles include a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and an electric motor 1220 that is driven by the supplied power from the main battery 1210 and is used during driving. The electric motor 1220 is typically a three-phase AC motor that drives the wheels 1250 during driving and functions as a generator during regeneration. In the case of a hybrid vehicle, the vehicle 1200 further includes an engine 1300 in addition to the electric motor 1220. In Figure 10 it, a charging port is shown as a charging part of the vehicle 1200, but it can be configured to have a plug.

[0180] The power conversion device 1100 has a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 for converting between DC and AC. The converter 1110 shown in this example boosts the input voltage of the main battery 1210, which is about 200 V or more and 300 V or less, to about 400 V or more and 700 V or less during driving of the vehicle 1200 and supplies power to the inverter 1120. The converter 1110 steps down the input voltage output from the electric motor 1220 via the inverter 1120 to a DC voltage suitable for the main battery 1210 and charges the main battery 1210 during regeneration. The input voltage is a DC voltage. The inverter 1120 converts the DC boosted by the converter 1110 into a specified AC and supplies power to the electric motor 1220 during driving of the vehicle 1200, and converts the AC output from the electric motor 1220 into DC and outputs it to the converter 1110 during regeneration.

[0181] As Figure 11As shown, 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 1115, and converts the input voltage by repeating on / off operations. The conversion of the input voltage here is to perform step-up / step-down conversion. The switching elements 1111 use power devices such as field effect transistors and insulated gate bipolar transistors. The reactor 1115 utilizes the property of a coil that impedes the change in the current flowing through the circuit, and has a function of smoothing the change when the current increases or decreases due to the switching operation. The reactor 1115 includes any one of the reactors 1 in Embodiments 1 and 2. By firmly holding the outer core 34 of the reactor 1 with the holding member 4, the power conversion device 1100 and the converter 1110 are excellent in productivity.

[0182] In addition to the converter 1110, the vehicle 1200 further includes a power supply converter 1150 connected to the main battery 1210, and an auxiliary power supply converter 1160 connected to the auxiliary battery 1230 and the main battery 1210 that is the power source for the accessories 1240 and converts the high voltage of the main battery 1210 into a low voltage. The converter 1110 typically performs DC-DC conversion, but the power supply converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. There is also a structure in the power supply converter 1150 that performs DC-DC conversion. The reactors of the power supply converter 1150 and the auxiliary power supply converter 1160 can utilize reactors having the same structure as the reactor 1 in Embodiments 1 and 2 and appropriately changed in size, shape, etc. Moreover, any one of the reactors 1 in Embodiments 1 and 2 can also be used in a converter that converts the input power and only performs step-up conversion or only performs step-down conversion.

[0183] Reference Numeral Explanation

[0184] 1 Reactor

[0185] 10 Assembly

[0186] 2 Coil

[0187] 21, 22 Winding Parts, 23 Connecting Part, 2a, 2b End Parts

[0188] 3 Magnetic Core

[0189] 31, 32 Inner Cores, 33, 34 Outer Cores

[0190] 3a Inner End Face, 3b Outer End Face, 3c First Outer Peripheral Face, 3d Second Outer Peripheral Face

[0191] 3e Third Outer Peripheral Face, 3f Fourth Outer Peripheral Face

[0192] 4 Holding Member

[0193] Inner side 4a, outer side 4b

[0194] Core storage part 40, bottom surface 40b, inner wall surface 40s

[0195] Through hole 41, coil storage part 42, core support part 43

[0196] Protrusion part 44, anti - detachment part 45

[0197] First holding part 5

[0198] Plate - shaped piece 50, first surface 50s, pressing parts 51, 52

[0199] Second holding part 6

[0200] Plate - shaped piece 60, second surface 60s

[0201] Core molding part 7

[0202] Clamping part 70, holding part 71, anti - detachment part 75

[0203] Outer molding part 8

[0204] Power conversion device 1100

[0205] Converter 1110, switching element 1111, drive circuit 1112

[0206] Reactor 1115, inverter 1120

[0207] Converter for power supply device 1150, converter for auxiliary machine power supply 1160

[0208] Vehicle 1200

[0209] Main battery 1210, motor 1220, auxiliary battery 1230

[0210] Auxiliary machines 1240, wheels 1250

[0211] Engine 1300.

Claims

1. A reactor includes an assembly formed by combining a coil, a magnetic core, and a holding member. The coil includes a winding portion formed by winding a winding. The magnetic core includes an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion. The holding member is disposed between an end face of the winding portion and the outer core portion. Among them, The holding member includes: An outer side face facing the side where the outer core portion is disposed; A concave core receiving portion into which a part of the outer core portion is inserted; and A first holding portion facing a first outer peripheral surface of the outer core portion. The first holding portion includes: A plate-like piece extending from the outer side face to the first outer peripheral surface; and A pressing portion pressing the first outer peripheral surface. The plate-like piece has a first surface flush with an inner wall surface of the core receiving portion. The pressing portion protrudes toward the first outer peripheral surface compared to the first surface. The pressing portion is a cantilever spring.

2. The reactor according to claim 1, wherein The pressing portion is a protrusion provided on the first surface, The protrusion extends in the depth direction of the core receiving portion.

3. The reactor according to claim 2, wherein The protruding amount of the protrusion protruding from the first surface increases as it approaches the bottom surface of the core receiving portion.

4. The reactor according to claim 2 or 3, wherein A cross-sectional shape of the protrusion orthogonal to the extending direction is a tapered shape that narrows as it approaches the protruding direction of the protrusion.

5. The reactor according to claim 1, wherein The cantilever spring is provided on a side of the plate-like piece.

6. The reactor according to claim 1 or 5, wherein A root portion of the cantilever spring is connected to the inner wall surface of the core receiving portion.

7. The reactor according to any one of claims 1 to 3, wherein The holding member includes a through hole penetrating the inner core portion, When the holding member is viewed from the outer side face side in a front view, the pressing portion is disposed at a position overlapping the through hole.

8. The reactor according to any one of claims 1 to 3, wherein The holding member includes a second holding portion extending along an axial direction of the winding portion from the outer side face, The second holding portion is disposed at a position facing the first holding portion with the core receiving portion therebetween.

9. The reactor according to any one of claims 1 to 3, wherein The reactor includes an outer molding portion covering at least a part of an outer periphery of the assembly.

10. A converter includes the reactor according to any one of claims 1 to 9.

11. A power conversion device includes the converter according to claim 10.

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