Reactor, converter, and power conversion device

Abstract

An electric reactor includes a coil having a winding portion formed by a plurality of turns, a first holding member arranged to face a first end surface of the winding portion, and a second holding member arranged to face a second end surface of the winding portion, the plurality of turns each being formed by a first straight portion, a first curved portion, a second straight portion, and a second curved portion arranged in this order about an axis of the winding portion, the first holding member and the second holding member each having two protruding portions that position the winding portion, the two protruding portions being formed by a first protruding portion that contacts at least a portion of the first curved portion and a second protruding portion that contacts at least a portion of the second curved portion.

Description

Technical Field

[0001] This invention relates to reactors, converters, and power conversion devices. This application claims priority based on Japan Patent Application No. 2023-198642 filed on November 22, 2023, and invokes all the contents set forth in the said Japanese application. Background Technology

[0002] Patent Document 1 discloses a reactor comprising a coil, a magnetic core, and a holding member. The coil comprises a main body consisting of multiple turns. Each turn has four straight portions with the winding arranged in a straight line and four corner portions with the winding bent. The holding member is disposed at each end of the main body to ensure electrical insulation between the main body and the magnetic core. The holding member has multiple inner protrusions for positioning the coil. The multiple inner protrusions are typically disposed at locations corresponding to each side of the inner circumferential surface of the main body. Existing technical documents Patent documents

[0003] Patent Document 1: Japanese Patent Application Publication No. 2022-188850 Summary of the Invention

[0004] The reactor of the present invention comprises: a coil having a wound portion consisting of a plurality of turns; a first retaining member disposed facing a first end face of the wound portion; and a second retaining member disposed facing a second end face of the wound portion. Each of the plurality of turns is configured to have a first straight portion, a first curved portion, a second straight portion, and a second curved portion arranged sequentially around the axis of the wound portion. The first retaining member and the second retaining member each have two protrusions that position the wound portion. The two protrusions are composed of a first protrusion that contacts at least a portion of the first curved portion and a second protrusion that contacts at least a portion of the second curved portion. Attached Figure Description

[0005] Figure 1 This is a simplified perspective view showing the reactor of embodiment 1. Figure 2 This is a simplified perspective view showing the assembled state of the coil, the first holding member, and the second holding member in the reactor of Embodiment 1. Figure 3 It means Figure 2 A simplified perspective view of the coil, the first holding member, and the second holding member in their disassembled state. Figure 4 It means Figure 2 A simplified top view of one turn of the coil. Figure 5 This is a simplified perspective view showing the core of the reactor in Embodiment 1. Figure 6 This is a simplified perspective view showing the relationship between the intermediate core and the first retaining member in the reactor of Embodiment 1. Figure 7 This is a simplified perspective view showing the reactor of embodiment 2. Figure 8 It means Figure 7 A simplified top view of one turn of the coil. Figure 9 This is a simplified perspective view showing the reactor of embodiment 3. Figure 10 This is a simplified perspective view showing the assembled state of the coil, the first holding member, and the second holding member in the reactor of Embodiment 3. Figure 11 It means Figure 10 A simplified perspective view of the coil, the first holding member, and the second holding member in their disassembled state. Figure 12 It means Figure 10 A simplified top view of one turn of the coil. Figure 13 This is a simplified perspective view showing the relationship between the intermediate core and the first retaining member in the reactor of Embodiment 3. Figure 14 This is a schematic diagram illustrating the power system configuration of a hybrid electric vehicle. Figure 15 This is a circuit diagram illustrating an example of a power conversion device equipped with a converter. Detailed Implementation

[0006] (The solution to be solved by this invention) A retaining member with high rigidity is required. In the retaining member disclosed in Patent Document 1, one or more inner protrusions are provided at each location corresponding to the four straight portions of the turn constituting the main body. The number of inner protrusions is large, and the size of each inner protrusion is small. Small inner protrusions have low rigidity, and the positioning accuracy of the coil is prone to deterioration. When the number of inner protrusions is large, the number of objects to check the formability of the inner protrusions, such as the presence or absence of nests and their size, increases, resulting in reduced productivity.

[0007] One object of the present invention is to provide a reactor with excellent rigidity and high productivity in the holding member for positioning the coil. Another object of the present invention is to provide a converter incorporating the above-mentioned reactor. Yet another object of the present invention is to provide a power conversion device incorporating the above-mentioned converter.

[0008] (Effects of the invention) The holding member for positioning the coil in the reactor of the present invention has excellent rigidity.

[0009] (Description of embodiments of the present invention) First, embodiments of the present invention will be described.

[0010] (1) The reactor according to an embodiment of the present invention comprises: a coil having a winding portion consisting of a plurality of turns; a first retaining member disposed facing a first end face of the winding portion; and a second retaining member disposed facing a second end face of the winding portion. Each of the plurality of turns is configured to have a first straight portion, a first curved portion, a second straight portion, and a second curved portion arranged sequentially around the axis of the winding portion. The first retaining member and the second retaining member each have two protrusions that position the winding portion. The two protrusions are composed of a first protrusion that contacts at least a portion of the first curved portion and a second protrusion that contacts at least a portion of the second curved portion.

[0011] Since the number of protrusions on the first or second retaining member located at the first end of a winding section is two, the number of objects requiring inspection of the protrusion's formability is small. Inspection of the protrusion's formability includes, for example, the presence or absence of nests and dimensional management. Reactors with fewer objects to be inspected exhibit superior productivity. Even though the number of protrusions on each of the first and second retaining members is two relative to each end of a winding section, the size of each protrusion is easily increased by providing these two protrusions in correspondence with the first and second curved portions in the turns constituting the winding section. The curved portion is a part consisting only of curves, excluding parts consisting of straight lines. Larger protrusions result in higher rigidity. Retaining members with large protrusions exhibit excellent rigidity.

[0012] (2) In the reactor described in (1) above, the first curved portion and the second curved portion may each have a semi-circular shape.

[0013] The turn, composed of a first straight section, a first curved section, a second straight section, and a second curved section, is suitable for a flat winding section. In particular, if the first curved section and the second curved section are each semi-circular in shape, it is easy to manufacture a flat winding section. If the winding section is flat, it is easy to manufacture a flat reactor.

[0014] (3) In the reactor described in (1) or (2) above, the first protrusion and the second protrusion may each have a shape that follows the inner circumference of the winding portion.

[0015] When the shapes of the first protrusion and the second protrusion are aligned with the inner circumference of the winding portion, that is, with the shapes of the first curved portion and the second curved portion, the first protrusion can easily support the first curved portion, and the second protrusion can easily support the second curved portion. Even with two protrusions, if both curved portions can be supported, the winding portion can be positioned with high precision.

[0016] (4) In any of the reactors described in (1) to (3) above, the coil may also be a flat vertical coil made of flat wire.

[0017] Flat, vertical coils made of flat wire can shorten the length of the winding section. The length of the winding section is the length along the axis of the winding section.

[0018] (5) In any of the reactors described in (1) to (4) above, the first length of the first straight section and the second straight section is longer than the second length between the first straight section and the second straight section.

[0019] The first winding section, which is longer than the second winding section, is flat. If the winding section is flat, the reactor as a whole can easily become flat. Flat reactors are easy to place in any space, offering excellent flexibility in configuration.

[0020] (6) The converter of the embodiment of the present invention includes the reactor described in any one of (1) to (5) above.

[0021] Converters equipped with the aforementioned reactors have excellent productivity.

[0022] (7) The power conversion device according to the embodiment of the present invention includes the converter described in (6) above.

[0023] The power conversion device equipped with the above converter has excellent productivity.

[0024] (Details of embodiments of the present invention) Specific examples of embodiments of the present invention are described below with reference to the accompanying drawings. Reference numerals in the drawings denote the same names for the same items. For ease of explanation, parts of the structure are sometimes exaggerated or simplified in the drawings. The dimensional ratios of the parts in the drawings may also differ from actual dimensions. It should be noted that the present invention is not limited to these illustrations, but is intended to include all modifications within the meaning and scope equivalent to the claims, as indicated by the claims.

[0025] (Implementation Method 1) Reference Figures 1 to 6 The reactor 1α of embodiment 1 is described. For example... Figure 1As shown, the reactor 1α includes a coil 2, a first holding member 5, a second holding member 6, and a magnetic core 8. The coil 2 has a winding portion 20 composed of a winding 3 with multiple turns 4. Figure 4 As shown, one feature of the reactor 1α is that each turn 4 is composed of a first straight section 41, a first curved section 43, a second straight section 42, and a second curved section 44. For example... Figure 3 and Figure 4 As shown, another feature of the reactor 1α is that the first retaining member 5 has two protrusions formed by a first protrusion 51 and a second protrusion 52. Yet another feature of the reactor 1α is that... Figure 2 and Figure 3 As shown, the second retaining member 6 has two protrusions, consisting of a first protrusion 61 and a second protrusion 62. The first protrusion 51 and the second protrusion 52 of the first retaining member 5, and the first protrusion 61 and the second protrusion 62 of the second retaining member 6 are provided in a number corresponding to the number of winding portions 20.

[0026] (coil) The coil 2 has at least one winding portion 20. In this example, the coil 2 has one winding portion 20. The winding portion 20 is constructed by winding the wire 3 into a spiral shape. Both ends of the wire 3 extend from each end of the winding portion 20. Terminal parts (not shown) are fitted to both ends of the wire 3 extending from the winding portion 20. An external device (not shown) is connected to the terminal parts. Only the winding portion 20 is shown in the figures; the two ends of the wire 3 are omitted.

[0027] The winding 3 can utilize known windings. In this example, the winding 3 is a flat wire having a conductor wire and an insulating sheath covering the conductor wire. The conductor wire is, for example, made of copper flat wire. The insulating sheath is, for example, made of enamel. In this example, the coil 2 is a flat, upright coil made of flat wire. A flat, upright coil made of flat wire can shorten the length along the axis of the winding portion 20. The length of the winding portion 20 refers to the length along the axis of the winding portion 20.

[0028] The winding section 20 is composed of multiple turns 4. For example... Figure 4 As shown, each turn 4 is composed of a first straight section 41, a first curved section 43, a second straight section 42, and a second curved section 44 arranged sequentially around the axis of the winding section 20. Figure 4 In the middle, it represents any one of multiple turns 4. Figure 4 In the diagram, double-dotted lines are used to virtually represent the transition points between adjacent turns 4. Figure 4 For ease of explanation, this indicates the state in which the first retaining member 5, described later, is assembled in the winding section 20.

[0029] The first straight section 41 and the second straight section 42 are vertically symmetrical and have the same length L1. Vertical symmetry means that if the first straight section 41 is rotated 180° around the axis of the winding section 20, it will align with the second straight section 42. The first straight section 41 and the second straight section 42 are parallel to each other. The first curved section 43 and the second curved section 44 are horizontally symmetrical and have the same length. Horizontal symmetry means that if the first curved section 43 is rotated 180° around the axis of the winding section 20, it will align with the second curved section 44. Figure 4 As shown, the outline shape of each turn 4, which is composed of the first straight section 41, the first curved section 43, the second straight section 42, and the second curved section 44, is a racetrack shape. The outline shapes of the first end face 21 and the second end face 22 of the winding section 20 are also racetrack shapes.

[0030] Here, three directions in the reactor 1α are defined with reference to the winding section 20. The three directions are the first direction D1, the second direction D2, and the third direction D3. The first direction D1 is along the axis of the winding section 20 from... Figure 3 The first end face 21 is shown facing the second end face 22. The second direction D2 is orthogonal to the first direction D1, and is from... Figure 4 The first curved section 43 is shown facing the second curved section 44. The third direction D3 is orthogonal to the first direction D1, and is from... Figure 4 The first straight section 41 shown faces the second straight section 42. Hereinafter, the opposite directions of the first direction D1, the second direction D2, and the third direction D3 are also referred to as the first direction D1, the second direction D2, and the third direction D3.

[0031] like Figure 4 As shown, the length L1 of each of the first straight section 41 and the second straight section 42 is, for example, longer than the length L2 between the first straight section 41 and the second straight section 42. Length L2 is the length along the third direction D3 between the facing surfaces of the first straight section 41 and the second straight section 42. The first curved section 43 is connected to the first end of the first straight section 41, and the second curved section 44 is connected to the second end of the first straight section 41. Length L1 is also the minimum length along the second direction D2 between the first curved section 43 and the second curved section 44. Length L2 is also the minimum length along the third direction D3 for connecting the ends of the first curved section 43 to each other.

[0032] The winding portion 20, whose length L1 is longer than its length L2, has a flat shape that thins in the third direction D3. The turn 4, composed of the first straight portion 41, the first curved portion 43, the second straight portion 42, and the second curved portion 44, is adapted to form the flat winding portion 20. In the flat winding portion 20, the ratio of length L2 to length L1, L2 / L1, is, for example, 1 / 10 or more and 1 / 3 or less. The ratio L2 / L1 can also be 1 / 10 or more and 1 / 4 or less, or 1 / 10 or more and 1 / 5 or less. If the winding portion 20 is flat, the reactor 1α as a whole can also easily become flat. The flat reactor 1α can be easily arranged in any space, offering excellent flexibility in its arrangement.

[0033] The first curved portion 43 and the second curved portion 44 each have, for example, a semi-circular shape. If the shapes of the first curved portion 43 and the second curved portion 44 are each semi-circular, it is easy to manufacture a flat winding portion 20. The first curved portion 43 and the second curved portion 44, excluding portions composed of straight lines, can be composed of any curve. The shapes of the first curved portion 43 and the second curved portion 44 can also be semi-elliptical. The first curved portion 43 and the second curved portion 44 are formed by bending the winding 3 along the outer circumference of an axis (not shown) during the manufacturing process of the coil 2. By changing the shape of this axis, the shapes of the first curved portion 43 and the second curved portion 44 can be formed as either semi-circular or semi-elliptical.

[0034] (First retaining member) like Figure 3 As shown, the first retaining member 5 is configured to face the first end face 21 of the winding portion 20. The first retaining member 5 has the function of ensuring electrical insulation between the winding portion 20 and the first end core portion 821 described later. The first retaining member 5 includes a main body portion 50, a first protrusion portion 51, and a second protrusion portion 52. In this example, the first retaining member 5 also includes a side portion 55.

[0035] The main body 50 is a plate-shaped member disposed between the winding section 20 and the first end core 821. The main body 50 has a through hole 50h penetrating both the inside and outside of the main body 50. The through hole 50h is provided for connecting the inner core 81 and the first end core 821, which will be described later. The shape of the through hole 50h is approximately similar to the outline shape of each turn 4. The outline shape of the through hole 50h is racetrack-shaped. The outline shape of the through hole 50h has a flat shape that thins in the third direction D3.

[0036] The first protrusion 51 and the second protrusion 52 serve to position the winding portion 20. Two protrusions are provided in the first retaining member 5 for positioning the winding portion 20. These two protrusions are the first protrusion 51 and the second protrusion 52. In other words, the first retaining member 5, apart from the first protrusion 51 and the second protrusion 52, does not have any other protrusions for positioning the winding portion 20.

[0037] The first protrusion 51 and the second protrusion 52 are disposed at mutually facing portions on the inner peripheral surface of the through hole 50h. The portion on the inner peripheral surface of the through hole 50h where the first protrusion 51 and the second protrusion 52 are disposed protrudes beyond the thickness of each of the first protrusion 51 and the second protrusion 52 relative to other portions. The first protrusion 51 and the second protrusion 52 protrude toward the second retaining member 6 along the first direction D1 from the surface of the main body 50 facing the first end face 21 of the winding portion 20. The protrusion length of the first protrusion 51 and the second protrusion 52 is, for example, a length that contacts two or more turns of the winding portion 20. This protrusion length is the length of the first protrusion 51 and the second protrusion 52 along the first direction D1, measured from the surface of the main body 5 facing the first end face 21. When the first protrusion 51 and the second protrusion 52 are disposed such that they contact two or more turns from each end of the winding portion 20, the coil 2 can be easily positioned with high precision using the first retaining member 5. In this example, the protruding lengths of the first protrusion 51 and the second protrusion 52 have a length that contacts the two turns of the winding portion 20.

[0038] The first protrusion 51 is configured to be in conjunction with Figure 4At least a portion of the first curved portion 43 is in contact. In this example, the first protrusion 51 is configured to contact the inner surface of the first curved portion 43. In this example, the first protrusion 51 has a shape that follows the inner circumferential shape of the winding portion 20. In this example, the outer circumferential surface of the first protrusion 51 and the inner circumferential surface of the winding portion 20 are coplanar. In this example, the first protrusion 51 has a shape that follows the inner surface shape of the first curved portion 43. In this example, the first curved portion 43 has a semi-circular shape, and the first protrusion 51 also has a semi-circular shape. If the first protrusion 51 has a shape that follows the inner surface shape of the first curved portion 43, a certain clearance may also be provided between the first protrusion 51 and the first curved portion 43. The first protrusion 51 may also be configured to contact a portion of the first straight portion 41 and a portion of the second straight portion 42 in addition to contacting the first curved portion 43. By configuring the first protrusion 51 to contact only the first curved portion 43, it is easier to assemble the first protrusion 51 into the winding portion 20. When viewed from the first direction D1, if the first protrusion 51 is configured to contact the entire surface of the first curved portion 43, then compared to contacting only a portion of the first curved portion 43, the first protrusion 51 has higher strength and can more easily and stably support the winding portion 20. The first protrusion 51 may also be configured to contact only a portion of the first curved portion 43. In this case, the first protrusion 51 may, for example, contact the outermost portion of the first curved portion 43 located in the second direction D2.

[0039] The second protrusion 52 is configured to be consistent with... Figure 4At least a portion of the second curved portion 44 is in contact. In this example, the second protrusion 52 is configured to contact the inner surface of the second curved portion 44. In this example, the second protrusion 52 has a shape that follows the inner circumferential shape of the winding portion 20. In this example, the outer circumferential surface of the second protrusion 52 and the inner circumferential surface of the winding portion 20 are coplanar. In this example, the second protrusion 52 has a shape that follows the inner surface shape of the second curved portion 44. In this example, the second curved portion 44 has a semi-circular shape, and the second protrusion 52 also has a semi-circular shape. Even though the second protrusion 52 has a shape that follows the inner surface shape of the second curved portion 44, some clearance may be provided between the second protrusion 52 and the second curved portion 44. The second protrusion 52 may also be configured to contact a portion of the first straight portion 41 and a portion of the second straight portion 42 in addition to contacting the second curved portion 44. By configuring the second protrusion 52 to contact only the second curved portion 44, it is easier to assemble the second protrusion 52 into the winding portion 20. When viewed from the first direction D1, if the second protrusion 52 is configured to contact the entire surface of the second curved portion 44, its strength is higher than that of contacting only a portion of the second curved portion 44, thus easily and stably supporting the winding portion 20. The second protrusion 52 may also be configured to contact only a portion of the second curved portion 44. In this case, the second protrusion 52 may, for example, contact the outermost portion of the second curved portion 44 located in the second direction D2.

[0040] The first protrusion 51 and the second protrusion 52 are, for example, symmetrical from left to right. Symmetry means that if the first protrusion 51 is rotated 180° around the axis of the winding portion 20, it will align with the second protrusion 52. The first protrusion 51 and the second protrusion 52 may also be asymmetrical. The protrusion lengths of the first protrusion 51 and the second protrusion 52 along the first direction D1 may also be different. The lengths of the first protrusion 51 and the second protrusion 52 around the axis of the winding portion 20 may also be different. The first protrusion 51 and the second protrusion 52 are configured to contact the outermost portions of the first curved portion 43 and the second curved portion 44. The first protrusion 51 and the second protrusion 52 may have an overlapping area facing each other, or they may not overlap entirely. The overlapping area of ​​the first protrusion 51 and the second protrusion 52 is the area that contacts the outermost portions of the first curved portion 43 and the second curved portion 44.

[0041] The first protrusion 51 may be configured to contact at least a portion of the outer surface of the first curved portion 43, and the second protrusion 52 may be configured to contact at least a portion of the outer surface of the second curved portion 44. In this case, the first protrusion 51 and the second protrusion 52 may each have a shape that follows the outer periphery of the winding portion 20.

[0042] Since the first retaining member 5 has two protrusions, a first protrusion 51 and a second protrusion 52, the number of objects to be inspected for the formability of these protrusions is small. Even though the first retaining member 5 has two protrusions, the rigidity of the first protrusion 51 and the second protrusion 52 is easily improved by aligning the first protrusion 51 with the first curved portion 43 and the second protrusion 52 with the second curved portion 44. The first retaining member 5, with its highly rigid first protrusion 51 and second protrusion 52, exhibits excellent rigidity.

[0043] like Figure 2 and Figure 3 As shown, the side portion 55 is configured to extend from one end of the main body portion 50 in a second direction D2 toward a first direction D1. The side portion 55 is disposed in... Figure 1 The side core portion 823 is shown between the winding portion 20. For example... Figure 3 As shown, the surface of side portion 55 facing the winding portion 20 is an arcuate surface along the outline of the winding portion 20. Alternatively, an engaging portion (not shown) may be provided at the top end of side portion 55 in the first direction D1. This engaging portion engages with an engaging portion (not shown) provided on side portion 65 of the second retaining member 6, which will be described later. For example... Figure 4 As shown, a gap 7 is provided between the side portion 55 and the winding portion 20. When the gap 7 is provided, it is easy to arrange the first protrusion 51 and the second protrusion 52 on the inner circumferential surface of the winding portion 20. When the gap 7 is provided, it is not necessary to make the interval between the first protrusion 51 and the side portion 55 correspond precisely to the width of the winding 3, and high forming precision is not required.

[0044] The side portion 55 has the function of determining the relative position of the first retaining member 5 and the second retaining member 6. In addition, when the side core portion 823 described later is made of composite material, the side portion 55 also has the function of preventing the composite material from contacting the winding portion 20 during the forming of the side core portion 823.

[0045] The first retaining member 5 is made of an electrically insulating material. This material may be, for example, polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin such as nylon 6 or nylon 66, polybutylene terephthalate (PBT) resin, or acrylonitrile-butadiene-styrene (ABS) resin. The material of the first retaining member 5 may also be a thermosetting resin such as unsaturated polyester resin, epoxy resin, polyurethane resin, or silicone resin. These resins may also contain ceramic fillers. Ceramic fillers may be, for example, non-magnetic powders such as alumina or silica.

[0046] (Second retaining member) like Figure 3As shown, the second retaining member 6 is configured to face the second end face 22 of the winding portion 20. The second retaining member 6 has the function of ensuring electrical insulation between the winding portion 20 and the second end core portion 822, which will be described later. The second retaining member 6 includes a main body portion 60, a first protrusion 61, and a second protrusion 62. The main body portion 60 is a plate-shaped member disposed between the winding portion 20 and the second end core portion 822. The main body portion 60 has a through hole 60h that penetrates both the inside and outside of the main body portion 60. In this example, the second retaining member 6 also includes a side portion 65.

[0047] The second retaining member 6 has the same structure as the first retaining member 5. The second retaining member 6 will be described by rereading the "main body 50", "through hole 50h", "first protrusion 51", "second protrusion 52" and "side 55" of the first retaining member 5 as "main body 60", "through hole 60h", "first protrusion 61", "second protrusion 62" and "side 65" respectively.

[0048] Since the protrusions provided on the second retaining member 6 are the first protrusion 61 and the second protrusion 62, the number of objects to be inspected for the formability of these protrusions is small. Even though there are two protrusions provided on the second retaining member 6, the rigidity of the first protrusion 61 and the second protrusion 62 is easily improved by having the first protrusion 61 correspond to the first curved portion 43 and the second protrusion 62 correspond to the second curved portion 44. The second retaining member 6, with its highly rigid first protrusion 61 and second protrusion 62, exhibits excellent rigidity.

[0049] In this example, the second retaining member 6 has the same shape and size as the first retaining member 5. If the second retaining member 6 is rotated 180° about an axis parallel to the second direction D2, it will be identical to the first retaining member 5. The first retaining member 5 and the second retaining member 6 can have parts with different shapes or sizes.

[0050] (Magnetic core) Coil 2 is configured in magnetic core 8. For example... Figure 5 As shown, the magnetic core 8 includes an inner core portion 81 and an outer core portion 82. The inner core portion 81 and the outer core portion 82 are configured as a series, thereby forming a closed magnetic circuit through which magnetic flux flows when the excitation coil 2 is activated. In this example, the magnetic core 8 is a one-piece molded body with the inner core portion 81 and the outer core portion 82 seamlessly integrated. The magnetic core 8 in this example is constructed from a molded composite material, as described later.

[0051] The inner core 81 is a portion disposed inside the winding portion 20 of the coil 2. The number of inner cores 81 is the same as the number of winding portions 20. Since there is only one winding portion 20 in this example, there is also only one inner core 81. The inner core 81 extends along the first direction D1. The end of the inner core 81 may also protrude from the end of the winding portion 20. This protruding portion is also part of the inner core 81. That is, the length of the inner core 81 along the first direction D1 may be longer than the length of the winding portion 20 along the first direction D1.

[0052] The shape of the inner core 81 roughly corresponds to the inner circumferential shape of the winding portion 20. For example... Figure 5 and Figure 6 As shown, in this example, two recesses 810 are provided at each of the two ends of the inner core 81. Figure 6 For ease of explanation, this indicates that the first retaining member 5 is assembled at the first end of the inner core 81. Figure 6 For ease of understanding, the following is not indicated. Figure 5 The outer core portion 82 is shown.

[0053] Two recesses 810 located at the first end of the inner core 81 are correspondingly provided with the first protrusion 51 and the second protrusion 52 provided on the first retaining member 5. A portion of the first end of the inner core 81 is embedded in a through hole 50h provided in the main body 50 of the first retaining member 5. When the first retaining member 5 is assembled to the first end of the inner core 81, the outer peripheral surface of the inner core 81, the outer surface of the first protrusion 51, and the outer surface of the second protrusion 52 are coplanar.

[0054] Two recesses 810 located at the second end of the inner core 81 and two recesses 810 located at the second end of the inner core 81 Figure 2 and Figure 3 The first protrusion 61 and the second protrusion 62 of the second retaining member 6 are correspondingly provided. A portion of the second end of the inner core 81 is embedded in the through hole 60h provided in the main body 60 of the second retaining member 6. When the second retaining member 6 is assembled to the second end of the inner core 81, the outer peripheral surface of the inner core 81, the outer surface of the first protrusion 61, and the outer surface of the second protrusion 62 are coplanar.

[0055] The outer core 82 is the portion disposed outside the winding portion 20 of the coil 2. The shape of the outer core 82 is not particularly limited as long as it is a shape that connects to the end of the inner core 81. Figure 1 and Figure 5As shown, the outer core portion 82 in this example includes a first end core portion 821, a second end core portion 822, and a side core portion 823. The first end core portion 821 is positioned facing the first retaining member 5 and is connected to the first end portion of the inner core portion 81. The second end core portion 822 is positioned facing the second retaining member 6 and is connected to the second end portion of the inner core portion 81. The side core portion 823 connects the first end core portion 821 and the second end core portion 822. Viewed from a third direction D3, the outer core portion 82 formed by connecting the first end core portion 821, the second end core portion 822, and the side core portion 823 has a rectangular C-shaped shape.

[0056] The magnetic core 8 in this example is composed of a molded composite material. The molded composite material is manufactured by filling a mold with a raw material in which soft magnetic powder is dispersed and mixed in uncured resin, and then allowing the resin to cure. The magnetic core 8 is manufactured, for example, as follows: [Manufacturing] Figure 2 The assembly shown consists of a first retaining member 5 and a second retaining member 6 assembled in the coil 2. This assembly is placed inside a mold. The aforementioned raw material is filled into the mold containing the assembly. The raw material is filled from a location corresponding to either the first end core 821 or the second end core 822. The raw material flows along the shape of the mold and the inner circumference of the winding portion 20. When the resin is cured, a shape is formed. Figure 5 The magnetic core 8 shown is manufactured... Figure 1 The reactor 1α shown. In the inner core 81, the recess 810 is in direct contact with the first protrusions 51, 61 and the second protrusions 52, 62, and the portion other than the recess 810 is in direct contact with the inner peripheral surface of the winding portion 20.

[0057] By adjusting the proportion of soft magnetic powder in the resin, the magnetic properties of the composite material can be easily controlled, such as permeability or saturation magnetic flux density. In particular, the composite material makes it easy to reduce the proportion of soft magnetic powder, thus lowering the permeability. Compared to the powder-molded body described later, the composite material is easier to mold even complex shapes. For the composite material molded body, it is easier to mold magnetic cores 8 corresponding to relatively complex shapes such as the first protrusion 51 and the second protrusion 52.

[0058] Soft magnetic powder is composed, for example, of soft magnetic metal particles, coated particles, or soft magnetic non-metal particles. The coated particles have soft magnetic metal particles and an insulating coating portion disposed around the periphery of the soft magnetic metal particles. The soft magnetic metal is, for example, pure iron or an iron-based alloy. The iron-based alloy is, for example, an Fe-Si alloy or an Fe-Ni alloy. The insulating coating portion is, for example, phosphate. The soft magnetic non-metal is, for example, ferrite. When the composite material is set to 100% by volume, the content of soft magnetic powder in the molded article of the composite material is, for example, 20% by volume or more and 80% by volume or less. The resin is, for example, PPS resin, PTFE resin, LCP, PA resin, PBT resin, or ABS resin. The resin can also be BMC (Bulk Molding Compound), a compounded silicone rubber, or a compounded polyurethane rubber, which is an unsaturated polyester mixed with calcium carbonate or glass fiber.

[0059] The magnetic core 8 can also be made of a powder-molded body. A magnetic core 8 made of a powder-molded body has multiple magnetic chips. The magnetic core 8 made of a powder-molded body has seams between the magnetic chips at any point. The magnetic core 8 can also be constructed by combining magnetic chips made of powder-molded bodies and magnetic chips made of composite material molding bodies. The magnetic core 8 can also be constructed by covering the outer periphery of the magnetic chips made of powder-molded bodies with a composite material.

[0060] Powder-molded bodies are formed by pressing together raw material powder containing soft magnetic powder. Compared with composite material molded bodies, powder-molded bodies can increase the proportion of soft magnetic powder in the molded body. Powder-molded bodies with a higher proportion of soft magnetic powder have higher magnetic permeability. When the powder-molded body is set to 100% by volume, the proportion of soft magnetic powder in the powder-molded body is, for example, more than 80% by volume, more than 85% by volume, more than 90% by volume, or more than 95% by volume. Lubricants may also be contained in the above-mentioned raw material powder.

[0061] (Implementation Method 2) Reference Figure 7 and Figure 8 The reactor 1β of Embodiment 2 is described below. The reactor 1β of Embodiment 2 differs from the reactor 1α of Embodiment 1 in the shape of the magnetic core 8, the shape of the first holding member 5, and the shape of the second holding member 6.

[0062] like Figure 7As shown, the outer core 82 in this example includes a first end core 821, a second end core 822, and two side cores 823 and 824. The two side cores 823 and 824 are configured to sandwich the winding portion 20. The side core 823 connects the first ends of the first end core 821 and the second end core 822 in the second direction D2 to each other. The side core 824 connects the second ends of the first end core 821 and the second end core 822 in the second direction D2 to each other. Viewed from the third direction D3, the outer core 82 formed by connecting the first end core 821, the second end core 822, and the two side cores 823 and 824 has a rectangular ring shape. Although the inner core in this example is not shown, it is connected to the central region of the first end core 821 and the second end core 822 in the second direction D2.

[0063] The magnetic core 8 in this example is the same as in Embodiment 1, and is a one-piece molded body with the inner core portion 81 and the outer core portion 82 seamlessly connected. The magnetic core 8 in this example is made of a molded body of composite material.

[0064] like Figure 7 and Figure 8 As shown, the first retaining member 5 in this example includes a main body 50, a first protrusion 51, a second protrusion 52, and two side portions 55 and 56. The two side portions 55 and 56 are arranged facing each other. Side portion 55 is provided to extend from a first end of the main body 50 in a second direction D2 towards a first direction D1. Side portion 55 is disposed between the side core portion 823 and the winding portion 20. The surface of side portion 55 facing the winding portion 20 is an arcuate surface along the outer shape of the winding portion 20. Side portion 56 is provided to extend from a second end of the main body 50 in a second direction D2 towards a first direction D1. Side portion 56 is disposed between the side core portion 824 and the winding portion 20. The surface of side portion 56 facing the winding portion 20 is an arcuate surface along the outer shape of the winding portion 20. For example, as shown... Figure 8 As shown, gaps 7 are provided between the side portion 55 and the winding portion 20, and between the side portion 56 and the winding portion 20.

[0065] The second retaining member 6 in this example is similar to the first retaining member 5, comprising a main body 60, a first protrusion, a second protrusion, and two side portions 65 and 66. The first and second protrusions are... Figure 2 and Figure 3 The first protrusion 61 and the second protrusion 62 shown are identical. If the second retaining member 6 in this example is rotated 180° about an axis parallel to the second direction D2, it becomes identical to the first retaining member 5 described above.

[0066] In this example, since the protrusions provided on the first retaining member 5 are both a first protrusion 51 and a second protrusion 52, the number of objects to be inspected for the formability of these protrusions is small. Even though there are two protrusions provided on the first retaining member 5, the rigidity of the first protrusion 51 and the second protrusion 52 is easily improved by the fact that the first protrusion 51 corresponds to the first curved portion 43 and the second protrusion 52 corresponds to the second curved portion 44. The first retaining member 5, with its highly rigid first protrusion 51 and second protrusion 52, exhibits excellent rigidity.

[0067] Similarly, since the protrusions provided on the second retaining member 6 are the first protrusion 61 and the second protrusion 62, the number of objects to be inspected for the formability of these protrusions is small. Even though the number of protrusions provided on the second retaining member 6 is two, the rigidity of the first protrusion 61 and the second protrusion 62 is easily improved by the fact that the first protrusion 61 corresponds to the first curved portion 43 and the second protrusion 62 corresponds to the second curved portion 44. The second retaining member 6, having highly rigid first protrusion 61 and second protrusion 62, exhibits excellent rigidity.

[0068] (Implementation Method 3) Reference Figures 9 to 13 The reactor 1γ of Embodiment 3 is described below. The reactor 1γ of Embodiment 3 has two winding portions 20. The reactor 1γ of Embodiment 3 differs from the reactor 1α of Embodiment 1 in the number of winding portions 20, the shape of the magnetic core 8, the shape of the first holding member 5, and the shape of the second holding member 6.

[0069] In this example, coil 2 has two winding sections 20. The two winding sections 20 have the same structure. Both winding sections 20 are formed by a single winding wire 3. Although not shown, the first ends of the two winding sections 20 are connected to each other. Each winding section 20 is composed of multiple turns 4. In any one of the winding sections 20, as... Figure 12 As shown, each turn 4 is composed of a first straight section 41, a first curved section 43, a second straight section 42, and a second curved section 44 arranged sequentially around the axis of the winding section 20. The structure of each winding section 20 is the same as that of the winding section 20 described in Embodiment 1.

[0070] In this example, the magnetic core 8 has... Figure 13 The two inner cores 81 shown are Figure 9 The outer core 82 is shown. Similar to Embodiment 1, the magnetic core 8 in this example is a seamlessly integrated piece consisting of two inner cores 81 and an outer core 82. The magnetic core 8 in this example is constructed from a molded composite material. Figure 13 For ease of understanding, the following is not indicated. Figure 9 The outer core portion 82 is shown.

[0071] The two inner cores 81 have the same structure. For example... Figure 13 As shown, two recesses 810 are provided at each of the two ends of each inner core portion 81. The two recesses provided at the first end of the inner core portion 81 are correspondingly provided with the first protrusion 51 and the second protrusion 52 provided on the first retaining member 5. Figure 13 For ease of explanation, this indicates that the first retaining member 5 is assembled at the first end of the inner core 81. Two recesses 810 located at the second end of the inner core 81 and... Figure 10 and Figure 11 The first protrusion 61 and the second protrusion 62 of the second retaining member 6 shown are provided correspondingly.

[0072] like Figure 9 As shown, the outer core 82 in this example has a first end core 821 and a second end core 822. The first end of each inner core 81 is connected to the first end core 821, and the second end of each inner core 81 is connected to the second end core 822. Viewed from the third direction D3, the magnetic core 8 formed by connecting the two inner cores 81 and the outer core 82 has a rectangular O-shape.

[0073] like Figure 11 and Figure 12 As shown, the first retaining member 5 in this example includes a main body 50, a first protrusion 51, a second protrusion 52, and a side portion 55. Two through holes 50h are provided in the main body 50. The two through holes 50h have the same structure. A first protrusion 51 and a second protrusion 52 are provided corresponding to each through hole 50h. In this example, two winding portions 20 are provided, and the first protrusion 51 and the second protrusion 52 are provided in a manner corresponding to each winding portion 20. Therefore, the first retaining member 5 in this example has two first protrusions 51 and two second protrusions 52. Even in this case, the number of protrusions provided relative to the first end of one winding portion 20 is two. In other words, apart from the first protrusions 51 and the second protrusions 52, no protrusions for positioning the winding portion 20 are provided relative to the first end of one winding portion 20.

[0074] The side portion 55 is positioned between the two through holes 50h. For example... Figure 9 As shown, the side portion 55 is disposed between the two winding portions 20. The surface of the side portion 55 facing the winding portion 20 is an arcuate surface along the outer shape of the winding portion 20. For example... Figure 12 As shown, a gap 7 is provided between the side portion 55 and each winding portion 20.

[0075] The second retaining member 6 in this example is the same as the first retaining member 5, having a main body 60, a first protrusion 61, a second protrusion 62, and a side portion 65. If the second retaining member 6 in this example is rotated 180° about an axis parallel to the second direction D2, it becomes identical to the first retaining member 5 described above.

[0076] In this example, the reactor 1γ has two winding portions 20. However, since the first retaining member 5 has only two protrusions, a first protrusion 51 and a second protrusion 52, relative to the first end of one winding portion 20, the number of objects to be inspected for the formability of these protrusions is small. Even though there are two protrusions relative to the first end of one winding portion 20, the rigidity of the first protrusion 51 and the second protrusion 52 is easily improved by having the first protrusion 51 correspond to the first curved portion 43 and the second protrusion 52 correspond to the second curved portion 44. The first retaining member 5, with its highly rigid first protrusion 51 and second protrusion 52, exhibits excellent rigidity.

[0077] Similarly, since the second retaining member 6 has two protrusions, a first protrusion 61 and a second protrusion 62, relative to the second end of a winding portion 20, the number of objects for which the formability of these protrusions needs to be inspected is small. Even though there are two protrusions relative to the second end of a winding portion 20, the rigidity of the first protrusion 61 and the second protrusion 62 is easily improved by having the first protrusion 61 correspond to the first curved portion 43 and the second protrusion 62 correspond to the second curved portion 44. The second retaining member 6, having highly rigid first protrusion 61 and second protrusion 62, exhibits excellent rigidity.

[0078] (Implementation Method 4) (Converter / Power Conversion Device) The aforementioned reactors 1α, 1β, and 1γ can be used to meet the following energizing conditions: For example, the maximum DC current is 100A or more and 1000A or less, the average voltage is 100V or more and 1000V or less, and the operating frequency is 5kHz or more and 100kHz or less. The aforementioned reactors 1α, 1β, and 1γ are typically used as components of converters installed in vehicles such as electric vehicles and hybrid vehicles, or as components of power conversion devices equipped with such converters.

[0079] like Figure 14As shown, a hybrid electric vehicle, electric vehicle, or similar vehicle 1200 includes a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and an electric motor 1220 used for driving by power supplied from the main battery 1210. The electric motor 1220 is typically a three-phase AC motor, which drives the wheels 1250 during driving and functions as a generator during regeneration. In the case of a hybrid electric vehicle, the vehicle 1200 also includes an engine 1300 in addition to the electric motor 1220. Figure 14 In the vehicle, the charging station is a socket, but it can be configured to have a plug.

[0080] The power conversion device 1100 includes a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 and performing DC-AC conversion. In this example, the converter 1110 boosts the input voltage of the main battery 1210 (between 200V and 300V) to between 400V and 700V to supply power to the inverter 1120 when the vehicle 1200 is in motion. During regeneration, the converter 1110 steps down the input voltage from the motor 1220 via the inverter 1120 to a DC voltage suitable for the main battery 1210 to charge it. The input voltage is DC. The inverter 1120 converts the DC boosted by the converter 1110 into a predetermined AC voltage to supply power to the motor 1220 when the vehicle 1200 is in motion, and converts the AC output from the motor 1220 into DC output to the converter 1110 during regeneration.

[0081] like Figure 15 As shown, the converter 1110 includes multiple switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor 1115, which transforms the input voltage by repeatedly switching on and off. This input voltage transformation refers to step-up and step-down conversion. The switching elements 1111 utilize power devices such as field-effect transistors and insulated-gate bipolar transistors. The reactor 1115 functions by utilizing the coil properties that impede changes in the current flowing through the circuit, thus smoothing the change in current due to switching operations. The reactor 1115 includes the aforementioned reactors 1α, 1β, and 1γ.

[0082] In addition to converter 1110, vehicle 1200 also includes a power supply converter 1150 connected to the main battery 1210, and an auxiliary power supply converter 1160 that converts the high voltage of the main battery 1210 to a low voltage. The auxiliary power supply converter 1160 is connected to the auxiliary battery 1230, which serves as the power source for auxiliary equipment 1240, and the main battery 1210. Converter 1110 typically performs DC-DC conversion, but power supply converter 1150 and auxiliary power supply converter 1160 perform AC-DC conversion. Power supply converter 1150 also includes a DC-DC converter. The reactors in power supply converter 1150 and auxiliary power supply converter 1160 can utilize reactors with the same structure as the aforementioned reactors 1α, 1β, and 1γ, but with appropriate changes in size, shape, etc. Furthermore, the aforementioned reactors 1α, 1β, and 1γ can also be used in converters that perform input power conversion, either boost converters or buck converters. Explanation of reference numerals in the attached figures

[0083] 1α, 1β, 1γ reactors 2 coils 20 Winding section 21 First end face 22 Second end face 3. Winding 4 turns 41 First straight section 42 Second straight section 43 First Curve Section 44 Second Curve Section 5 First retaining member 50 Main body 50h through hole 51 First protrusion 52 Second protrusion 55, 56 Side 6 Second retaining member 60 Main body 60h through hole 61 First protrusion 62 Second protrusion 65, 66 Side 7 gaps 8 magnetic cores 81 Inner Core 810 recess 82 Outer core 821 First end core 822 Second end core 823, 824 Side Core L1, L2 lengths D1 First Direction, D2 Second Direction, D3 Third Direction 1100 Power conversion device, 1110 Converter, 1111 Switching element 1112 Drive circuit, 1115 Reactor, 1120 Inverter 1150 Converter for power supply unit, 1160 Converter for auxiliary power supply 1200 vehicle, 1210 main battery, 1220 electric motor 1230 Secondary batteries, 1240 Auxiliary equipment, 1250 Wheels, 1300 Engines

Claims

1. A reactor, comprising: A coil having a winding portion consisting of multiple turns of wire; A first retaining member is configured to face the first end face of the wound portion; and The second retaining member is configured to face the second end face of the winding portion. The plurality of turns are arranged in sequence around the axis of the winding portion, consisting of a first straight section, a first curved section, a second straight section, and a second curved section. The first retaining member and the second retaining member each have two protrusions that position the winding portion. The two protrusions are composed of a first protrusion that contacts at least a portion of the first curved portion and a second protrusion that contacts at least a portion of the second curved portion.

2. The reactor according to claim 1, wherein, The first curved portion and the second curved portion each have a semi-circular shape.

3. The reactor according to claim 1 or claim 2, wherein, The first protrusion and the second protrusion each have a shape that follows the inner circumference of the winding portion.

4. The reactor according to any one of claims 1 to 3, wherein, The coil is a flat, upright coil made of flat wire.

5. The reactor according to any one of claims 1 to 4, wherein, The first length of each of the first straight section and the second straight section is longer than the second length between the first straight section and the second straight section.

6. A converter comprising the reactor according to any one of claims 1 to 5.

7. A power conversion device comprising the converter of claim 6.

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