Reactor, converter, and power conversion device

Abstract

To provide a reactor that is compact and ensures sufficient electrical insulation from an attachment surface.SOLUTION: A reactor includes a coil having a winding portion, a magnetic core having an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion, and a spacer disposed between an end face of the winding portion and the outer core portion. The outer core portion has a first surface perpendicular to a first direction, the first direction being a direction intersecting an axis of the winding portion. The spacer extends along the first surface and includes a first overhang portion overlapping the first surface, and a first convex portion protruding toward the first direction. The first convex portion protrudes in the first direction beyond the outer core portion and the winding portion.SELECTED DRAWING: Figure 1

Description

[Technical field]

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

[0002] Patent Document 1 discloses a reactor including a coil having a winding portion and a magnetic core. In the reactor of Patent Document 1, a resin molded portion is formed to cover the magnetic core, and a fixing portion is formed in the resin molded portion. The fixing portion is configured to fix the reactor to a mounting surface of an object on which the reactor is to be placed. The resin molded portion ensures electrical insulation between the winding portion and the magnetic core, and also ensures electrical insulation between the magnetic core and the object on which the reactor is placed. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-5088 A Summary of the Invention [Problem to be solved by the invention]

[0004] When the space in which a reactor is to be installed is small, it is necessary to make the reactor smaller. However, if the resin molded portion is omitted in order to make the reactor smaller, there is a risk that the current flowing through the coil will be conducted to the mounting surface via the magnetic core.

[0005] One object of the present disclosure is to provide a reactor that is small and can ensure sufficient electrical insulation from a mounting surface. [Means for solving the problem]

[0006] The reactor of the present disclosure includes: A coil having a winding portion; a magnetic core having an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion; a spacer disposed between an end face of the winding portion and the outer core portion, the outer core portion has a first surface perpendicular to a first direction, the first direction being a direction intersecting an axis of the winding portion, The spacer is A first overhanging portion extending along the first surface and overlapping the first surface; a first protrusion protruding in the first direction, The first convex portion protrudes in the first direction further than the outer core portion and the winding portion. Effect of the Invention

[0007] The reactor of the present disclosure is a small reactor that ensures sufficient electrical insulation from the mounting surface. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic perspective view of a reactor according to a first embodiment, seen obliquely from above. [Diagram 2] FIG. 2 is a schematic perspective view of the reactor shown in FIG. 1 as viewed obliquely from below. [Diagram 3] FIG. 3 is a cross-sectional view taken along line III-III of FIG. [Figure 4] FIG. 4 is a schematic perspective view of a spacer provided in the reactor shown in FIG. [Diagram 5] FIG. 5 is an explanatory diagram for explaining a creepage distance in the reactor according to the first embodiment. [Figure 6] FIG. 6 is a schematic diagram showing an arrangement of reactors in a case having a long and narrow space. [Figure 7] FIG. 7 is a schematic diagram showing the power supply system of a hybrid vehicle. [Figure 8] FIG. 8 is a circuit diagram showing an example of a power conversion device including a converter. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] [Description of the embodiments of the present disclosure] First, the embodiments of the present disclosure will be listed and described.

[0010] <1> The reactor according to the embodiment has: A coil having a winding portion; a magnetic core having an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion; a spacer disposed between an end face of the winding portion and the outer core portion, the outer core portion has a first surface perpendicular to a first direction, the first direction being a direction intersecting an axis of the winding portion, The spacer is A first overhanging portion extending along the first surface and overlapping the first surface; a first protrusion protruding in the first direction, The first convex portion protrudes in the first direction further than the outer core portion and the winding portion.

[0011] By arranging the reactor on the mounting surface so that the first convex portion of the reactor contacts the mounting surface, the reactor can be placed directly on the mounting surface. In this case, electrical insulation between the outer core portion of the magnetic core and the mounting surface is ensured by the first convex portion and the first overhanging portion. Therefore, the above reactor does not require a molded resin portion that covers the magnetic core. A reactor that does not have a molded resin portion that covers the magnetic core is small and can be arranged, for example, in a long and narrow space.

[0012] <2> the above <1> In the reactor described in the first surface includes a planar portion and a recess; The first overhanging portion is disposed in the recessed portion, The flat portion and a surface of the first overhanging portion facing the first direction may be flush with each other.

[0013] By arranging the first overhanging portion in the recess, the thickness of the reactor in the first direction becomes thin, making such a reactor easy to arrange in, for example, a long and narrow space.

[0014] <3> the above <1> or <2> In the reactor described in A creepage distance from the first convex portion along a surface of the spacer to the outer core portion may be 4 mm or more.

[0015] If the creepage distance is 4 mm or more, sufficient electrical insulation between the outer core portion and the mounting surface is ensured.

[0016] <4> the above <1> from <3> In the reactor described in any one of the above, A surface of the first overhanging portion facing the first direction and a surface of the winding portion facing the first direction may be flush with each other.

[0017] the above <4> According to the configuration described in , the winding portion can be made large without contacting the mounting surface, and as a result, a sufficient cross-sectional area of ​​the magnetic path of the inner core portion disposed inside the winding portion can be secured.

[0018] <5> the above <1> from <4> In the reactor described in any one of the above, The inner core portion is made of a composite material in which soft magnetic powder is dispersed in a resin, The inner core portion may be in contact with an inner circumferential surface of the winding portion.

[0019] The above configuration <5> According to the configuration described in the above, the inner core portion can be fabricated simply by filling the interior of the winding portion with a composite material. Also, the magnetic path cross-sectional area of ​​the inner core portion disposed inside the winding portion can be increased.

[0020] <6> the above <5> In the reactor described in The outer core portion is made of the composite material, The inner core portion and the outer core portion may be integral.

[0021] the above <6> According to the configuration described in the above, the inner core portion and the outer core portion can be produced at the same time, thereby improving the productivity of the reactor.

[0022] <7> the above <1> from <6> In the reactor described in any one of the above, The winding portion may have a flat shape that is thinned in the first direction.

[0023] the above <7> According to the configuration described in the above, when the reactor is disposed on the mounting surface, the height of the reactor in the vertical direction of the mounting surface can be reduced. Such a reactor can be easily disposed in, for example, a long and narrow space.

[0024] <8> the above <1> from <7> In the reactor described in any one of the above, The outer core portion has a second surface facing a second direction opposite to the first direction, The spacer is A second overhanging portion extending along the second surface and overlapping the second surface; a second protrusion protruding in the second direction, The second convex portion may protrude in the second direction further than the outer core portion and the winding portion.

[0025] the above <8> According to the configuration described in the above, the reactor can be arranged so as to be fitted into the elongated space. The elongated space has a first mounting surface and a second mounting surface facing each other. In this case, the reactor is arranged so that the first convex portion and the second convex portion contact the first mounting surface and the second mounting surface, respectively. Electrical insulation between the first mounting surface and the outer core portion is ensured by the first convex portion and the first overhang portion, and electrical insulation between the second mounting surface and the outer core portion is ensured by the second convex portion and the second overhang portion.

[0026] <9> The converter of the present disclosure is <1> from <8> The present invention is provided with a reactor as described in any one of the above.

[0027] The reactor according to the embodiment is small and lightweight, and therefore the converter including the reactor according to the embodiment is also small and lightweight.

[0028] <10> The power conversion device of the present disclosure is <9> The converter is provided as described in.

[0029] The converter according to the embodiment is small and lightweight, and therefore the power conversion device including the converter according to the embodiment is also small and lightweight.

[0030] [Details of the embodiment of the present disclosure] Hereinafter, embodiments of a reactor, a converter, and a power conversion device according to the present disclosure will be described with reference to the drawings. The same reference numerals in the drawings indicate the same objects. Note that the present invention is not limited to the configurations shown in the embodiments, but is indicated by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0031] <Embodiment 1> 1 and 2 includes a coil 2, a magnetic core 3, and spacers 4 and 5. One of the features of this example is the configuration of the spacers 4 and 5. The reactor 1 of the present disclosure will be described in detail below.

[0032] <Coil> The coil 2 has at least one winding portion 21. The coil 2 in this example has one winding portion 21. The winding portion 21 is formed by winding a wire in a spiral shape. A known winding can be used for the winding. The winding in this embodiment is a coated rectangular wire made of a conductor wire having an insulating coating. The conductor wire is made of, for example, a rectangular copper wire. The insulating coating is made of, for example, enamel. The winding portion 21 in this example is an edgewise coil made by winding a coated rectangular wire edgewise.

[0033] The shape of the winding portion 21 is a square tube. That is, the end face shape of the winding portion 21 in this example is a rectangular frame shape. The corners of the winding portion 21 in this example are rounded. Furthermore, the winding portion 21 in this example has a flat shape that is rectangular when the winding portion 21 is viewed along the axis of the winding portion 21.

[0034] Here, the directions in reactor 1 are defined with coil 2 as a reference. First, the direction from the first end to the second end of winding portion 21 along the axis of winding portion 21 is the X1 direction. The direction from the first side to the second side of winding portion 21 is the Y1 direction. The Y1 direction is perpendicular to the X1 direction. The first side and the second side are faces that form the short side when flat winding portion 21 is viewed in the X1 direction. The direction perpendicular to the X1 direction and the Y1 direction is the Z1 direction. The X2 direction, the Y2 direction, and the Z2 direction are the opposite direction to the X1 direction, the opposite direction to the Y1 direction, and the opposite direction to the Z1 direction, respectively.

[0035] The winding portion 21 in this example has a flat shape that is thinned in the first direction. The first direction in this example coincides with the Z1 direction as described in the description of the outer core portion 32 below. When this flat winding portion 21 is viewed in the X1 direction, if the length of the winding portion 21 along the Y1 direction is the width W of the winding portion 21 and the length of the winding portion 21 along the Z1 direction is the height H of the winding portion 21, the ratio H / W of the width W to the height H of the winding portion 21 is, for example, 1 / 20 or more and less than 1. The ratio H / W may be 1 / 15 or more and less than 1, or 1 / 10 or more and less than 1. The winding portion 21 having such a flat shape is easy to arrange in an elongated space 90 as shown in FIG. 6.

[0036] Ends 22, 23 of the winding are pulled out from the winding portion 21. In this example, both end 22 and end 23 are pulled out from the winding portion 21 in the Y2 direction. The insulating coating is removed from ends 22, 23 to expose the conductor wire. A terminal member (not shown) is connected to the exposed conductor wire. Ends 22, 23 are within the range of height H of winding portion 21. Therefore, ends 22, 23 do not increase the dimension of winding portion 21 in the Z1 direction.

[0037] Unlike this example, when there are, for example, two winding portions 21, the two winding portions 21 may be connected to independent power sources, or may be connected to a single power source.

[0038] <Magnetic core> The magnetic core 3 is a magnetic body in which a closed magnetic circuit is formed. The magnetic core 3 is a powder compact or a composite material compact. The magnetic core 3 may be formed by combining a core piece made of a powder compact with a core piece made of a composite material compact, or by covering the outer periphery of a core piece made of a powder compact with a composite material.

[0039] The green compact is a product of pressure molding raw powder containing soft magnetic powder. The soft magnetic powder is, for example, pure iron or an iron alloy. The iron alloy is, for example, an Fe (iron)-Si (silicon) alloy or an Fe-Ni (nickel) alloy. The raw powder may contain a lubricant. The content of the soft magnetic powder in the green compact is, for example, more than 80 volume %, or even 85 volume % or more, when the entire green compact is taken as 100 volume %.

[0040] The composite material compact is a product of filling a mold with a mixture of soft magnetic powder and unsolidified resin, and solidifying the resin. In the composite material compact, the soft magnetic powder is dispersed in the resin. Examples of the resin include 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, and acrylonitrile butadiene styrene (ABS) resin. The resin may be BMC (bulk molding compound) in which calcium carbonate or glass fiber is mixed with unsaturated polyester, millable silicone rubber, or millable urethane rubber. The content of the soft magnetic powder in the composite material is, for example, 30% by volume or more and 80% by volume or less, when the entire composite material is taken as 100% by volume. The content of the soft magnetic powder in the composite material may further be 50% by volume or more, 60% by volume or more, or 70% by volume or more.

[0041] As shown in FIG. 3, the magnetic core 3 includes an inner core portion 31 and an outer core portion 32. In FIG. 3, the boundary between the inner core portion 31 and the outer core portion 32 is indicated by a two-dot chain line. The inner core portion 31 is disposed inside the winding portion 21 of the coil 2 and is aligned along the axis of the winding portion 21. The number of inner core portions 31 is the same as the number of the winding portions 21. Since the number of the winding portions 21 in this example is one, the number of the inner core portions 31 in this example is also one. In this example, both ends of the portion of the magnetic core 3 that is aligned along the axis of the winding portion 21 protrude from the end faces of the winding portion 21. The protruding portions are also part of the inner core portion 31.

[0042] The outer core portion 32 is a portion of the magnetic core 3 that is disposed outside the winding portion 21. The shape of the outer core portion 32 is not particularly limited as long as it connects the ends of the inner core portion 31. As shown in FIG. 1 and FIG. 2, the outer core portion 32 of this example is composed of an end core portion 321 facing an end face of the winding portion 21 in the X1 direction, an end core portion 322 facing an end face of the winding portion 21 in the X2 direction, and a side core portion 323 facing a side surface of the winding portion 21 in the Y1 direction. This outer core portion 32 is a rectangular C-shaped portion when viewed in the Z2 direction. Unlike this example, the number of side core portions may be two. In that case, the outer core portion 32 includes a side core portion facing a side surface of the winding portion 21 in the Y2 direction in addition to the side core portion 323. Such an outer core portion 32 is a rectangular ring shape when viewed in the Z2 direction. In addition, when the number of winding portions 21 and the number of inner core portions 31 are two, the outer core portion 32 is composed of, for example, an end core portion connecting the X1-direction ends of the two inner core portions 31, 31, and an end core portion connecting the X2-direction ends of the two inner core portions 31, 31.

[0043] The outer core portion 32 has a first surface 33 (FIG. 1) facing a first direction and a second surface 34 (FIG. 2) facing a second direction. The first surface 33 is a surface parallel to the surface of the winding portion 21 having the largest area when the winding portion 21 is viewed from a direction along one of the axes of a three-dimensional orthogonal coordinate system in which the axis of the winding portion 21 is the X-axis. The first direction is a direction intersecting the axis of the winding portion 21. For example, the first direction is a direction perpendicular to the axis of the winding portion 21 and toward the mounting surface to which the reactor 1 is mounted. In this example, the Z1 direction is the first direction. The second direction is the opposite direction to the first direction. In this example, the Z2 direction is the second direction. Unlike this example, the Z2 direction may be the first direction, the Y1 direction may be the first direction, or the Y2 direction may be the first direction.

[0044] As shown in FIG. 1, the first surface 33 of this example is composed of the surfaces of the two end core portions 321 and 322 facing the Z1 direction and the surface of the side core portion 323 facing the Z1 direction. That is, the first surface 33 of this example is C-shaped when viewed in the Z2 direction. As shown in FIG. 3, the first surface 33 includes a flat portion 33s, a recessed portion 33c formed at the position of the end core portion 321, and a recessed portion 33c formed at the position of the end core portion 322. Most of the first surface 33 is the flat portion 33s. The flat portion 33s is parallel to the XY plane. Of the two recessed portions 33c, the recessed portion 33c arranged in the X1 direction is formed in a portion of the end core portion 321 closer to the winding portion 21. On the other hand, the recessed portion 33c arranged in the X2 direction is formed in a portion of the end core portion 322 closer to the winding portion 21. The two recesses 33c, 33c are recessed in the Z2 direction, that is, in the second direction, from the flat surface portion 33s. First overhanging portions 40, 50 of the spacers 4, 5, which will be described later, are disposed in the recesses 33c, 33c.

[0045] As shown in FIG. 2, the second surface 34 of this example is composed of the surfaces of the two end core portions 321 and 322 facing the Z2 direction and the surface of the side core portion 323 facing the Z2 direction. That is, the second surface 34 of this example is C-shaped when viewed in the Z1 direction. As shown in FIG. 3, the second surface 34 includes a flat portion 34s, a recessed portion 34c formed at the position of the end core portion 321, and a recessed portion 34c formed at the position of the end core portion 322. Most of the second surface 34 is the flat portion 34s. The flat portion 34s is parallel to the XY plane. Of the two recessed portions 34c, the recessed portion 34c arranged in the X1 direction is formed in a portion of the end core portion 321 closer to the winding portion 21. On the other hand, the recessed portion 34c arranged in the X2 direction is formed in a portion of the end core portion 322 closer to the winding portion 21. The two recessed portions 34c, 34c are recessed in the Z1 direction, i.e., the first direction, from the flat portion 34s. In the recesses 34c, 34c, second overhanging portions 42, 52 of the spacers 4, 5, which will be described later, are disposed.

[0046] The magnetic core 3 of this example is formed by a molding of a composite material. More specifically, the inner core portion 31 and the outer core portion 32 are an integral body made of a composite material. Such a magnetic core 3 is produced by filling the composite material into a mold in which the coil 2 is arranged.

[0047] The composite material filled inside the winding portion 21 constitutes the inner core portion 31. This inner core portion 31 contacts the inner circumferential surface 21s of the winding portion 21. In this case, no other member is disposed between the inner circumferential surface 21s of the winding portion 21 and the inner core portion 31. Therefore, a large magnetic path cross-sectional area of ​​the inner core portion 31 in the winding portion 21 is ensured. Here, if there is a defect such as a pinhole in a part of the insulating coating of the winding that constitutes the winding portion 21, there is a possibility that the conductor wire of the winding and the inner core portion 31 will partially contact each other. However, even if the conductor wire and the inner core portion 31 locally contact each other, the characteristics of the reactor 1 will only be slightly deteriorated, and the contact will not be a major problem.

[0048] The composite material filled outside the winding portion 21 in the mold constitutes the outer core portion 32. The outer periphery of the outer core portion 32 is not molded with resin or the like and is exposed to the outside of the reactor 1. In other words, the outer peripheral surface of the outer core portion 32 constitutes a part of the outer peripheral surface of the reactor 1. If this bare outer core portion 32 is in direct contact with the mounting surface on which the reactor 1 is mounted, a conductive path is formed from the outer core portion 32 to the mounting surface. If a current leaks from the conductor wire of the winding portion 21 to the inner core portion 31 and the outer core portion 32 is in contact with the mounting surface, the current may cause a ground fault and the reactor 1 may not operate. In this example, spacers 4 and 5, which will be described later, ensure electrical insulation between the outer core portion 32 and the mounting surface.

[0049] <Spacer> The reactor 1 of this example includes two spacers 4, 5. The spacer 4 is disposed between the end face of the winding portion 21 and the end core portion 321 of the outer core portion 32. The spacer 5 is disposed between the end face of the winding portion 21 and the end core portion 322 of the outer core portion 32. These spacers 4, 5 ensure electrical insulation between the winding portion 21 and the outer core portion 32.

[0050] The spacers 4 and 5 are made of an electrically insulating material. Examples of such materials include PPS resin, PTFE resin, LCP, PA resin, PBT resin, and ABS resin. Alternatively, the spacers 4 and 5 may be made of a thermosetting resin such as an unsaturated polyester resin, an epoxy resin, a urethane resin, or a silicone resin. These resins may contain a ceramic filler. The ceramic filler may be a non-magnetic powder such as alumina or silica.

[0051] As shown in the schematic perspective view of Fig. 4, the spacer 4 includes a through hole 4h, a first overhanging portion 40, a first convex portion 41, a second overhanging portion 42, and a second convex portion 43 (see Figs. 2 and 3). The through hole 4h serves as a passage for the composite material when the magnetic core 3 is molded from the composite material. The inner core portion 31 and the outer core portion 32 are connected at the position of the through hole 4h.

[0052] 3, the first overhanging portion 40 extends along the first surface 33 of the outer core portion 32 and overlaps the first surface 33. As will be described later, the first overhanging portion 40 serves to ensure a creepage distance between the mounting surface, on which the reactor 1 is mounted, and the outer core portion 32.

[0053] The first overhanging portion 40 is disposed in a recess 33c of the first surface 33. The first overhanging portion 40 is fitted into the recess 33c. A surface of the first overhanging portion 40 facing the first direction is flush with the flat surface portion 33s of the first surface 33. The first direction coincides with the Z1 direction. By disposing the first overhanging portion 40 in the recess 33c, the thickness of the reactor 1 along the Z1 direction is reduced.

[0054] The surface of the first overhanging portion 40 facing the first direction and the surface of the winding portion 21 facing the first direction are flush with each other. In this case, the winding portion 21 can be made large to the extent that the winding portion 21 does not contact the mounting surface. Therefore, a sufficient magnetic path cross-sectional area of ​​the inner core portion 31 disposed inside the winding portion 21 is ensured.

[0055] The first convex portion 41 protrudes in the first direction. This first convex portion 41 protrudes in the first direction further than the outer core portion 32 and the winding portion 21. This first convex portion 41 contacts the mounting surface of the reactor 1, thereby preventing the winding portion 21 of the coil 2 and the outer core portion 32 from contacting the mounting surface.

[0056] The height of first convex portion 41 in the first direction is, for example, 0.01 mm or more and 2 mm or less. If the height is 0.01 mm or more, it is easy to ensure the insulation distance between the mounting surface and winding portion 21 and between winding portion 21 and outer core portion 32. If the height is 2 mm or less, the dimension of reactor 1 in the first direction does not become too large. The height may be, for example, 0.05 mm or more and 1 mm or less, or 0.1 mm or more and 0.5 mm or less.

[0057] 1 and 4, the number of the first convex portion 41 may be one or more. In this example, the number of the first convex portion 41 is two. Of course, the number of the first convex portion 41 may be three or more.

[0058] There is no particular limitation on the shape of the first convex portion 41. In this example, the first convex portion 41 has a rectangular truncated pyramid shape that is elongated in the Y1 direction. Unlike this example, the first convex portion 41 may have a circular truncated cone shape or a truncated pyramid shape other than a rectangular shape.

[0059] As shown in FIG. 5, the first convex portion 41 has an end face 41e and a side wall face 41s. The end face 41e is a face that contacts the mounting surface. The side wall face 41s is a face that connects the end face 41e and a face of the spacer 4 that faces the first direction except for the first convex portion 41. The creeping distance from the outer peripheral edge of the end face 41e along the surface of the spacer 4 to the outer core portion 32 is, for example, 4 mm or more. The creeping distance in this example is the shortest distance from the outer peripheral edge of the end face 41e along the side wall face 41s and the surface of the first overhanging portion 40 to the edge of the first overhanging portion 40 in the X1 direction, as shown by the double-sided arrow bent in FIG. 5. If the creeping distance is 4 mm or more, sufficient electrical insulation between the outer core portion 32 and the mounting surface is ensured. Depending on the degree of contamination of the surrounding environment or the operating voltage, the creeping distance may be, for example, 5 mm or more, 7 mm or more, or 10 mm or more. The longer the creepage distance, the easier it is to ensure electrical insulation between the outer core portion 32 and the mounting surface.

[0060] 2 and 3 are different from the first overhanging portion 40 and the first convex portion 41 only in the position and orientation in which they are formed, and have the same function as the first overhanging portion 40 and the first convex portion 41. Here, only the position and orientation in which the second overhanging portion 42 and the second convex portion 43 are formed will be described.

[0061] 3, the second overhanging portion 42 extends along the second surface 34 of the outer core portion 32 and overlaps with the second surface 34. The second overhanging portion 42 is disposed in a recess 34c of the second surface 34. The second overhanging portion 42 is fitted into the recess 34c. The surface of the second overhanging portion 42 facing the second direction is flush with the flat surface portion 34s of the second surface 34. The surface of the second overhanging portion 42 facing the second direction is flush with the surface of the winding portion 21 facing the second direction. The second direction coincides with the Z2 direction.

[0062] The second convex portion 43 protrudes in the second direction. The second convex portion 43 protrudes in the second direction further than the outer core portion 32 and the wound portion 21.

[0063] The height of the second convex portion 43 in the second direction is, for example, 0.01 mm or more and 2 mm or less. The height may be 0.05 mm or more and 1 mm or less, or 0.1 mm or more and 0.5 mm or less.

[0064] 2, the number of the second convex portion 43 may be one or more. In this example, the number of the second convex portion 43 is two. The shape of the second convex portion 43 is not particularly limited. In this example, the second convex portion 43 has a rectangular pyramid shape that is elongated in the Y1 direction.

[0065] The creepage distance from the second convex portion 43 to the outer core portion 32 may be, for example, 4 mm or more, or may be 5 mm or more, 7 mm or more, or 10 mm or more depending on the degree of pollution of the surrounding environment or the operating voltage. The creepage distance of the second convex portion 43 is the same as that of the first convex portion 41. The creepage distance of the second convex portion 43 is the same as that of the first convex portion 41 in the description of the first convex portion 41 with reference to FIG. 5, except that "first convex portion 41" is replaced with "second convex portion 43."

[0066] As shown in the schematic perspective view of Fig. 4, the spacer 5 includes a through hole 5h, a first overhanging portion 50, a first convex portion 51, a second overhanging portion 52, and a second convex portion 53 (see Figs. 2 and 3). The explanation of the spacer 5 can be made by replacing "through hole 4h", "first overhanging portion 40", "first convex portion 41", "second overhanging portion 42", and "second convex portion 43" in the explanation of the spacer 4 with "through hole 5h", "first overhanging portion 50", "first convex portion 51", "second overhanging portion 52", and "second convex portion 53", respectively.

[0067] The spacer 5 further includes a side portion 54. The side portion 54 extends in the X1 direction from an end of the spacer 5 in the Y1 direction. As shown in FIG. 1, the side portion 54 is disposed between the winding portion 21 and the side core portion 323. The surface of the side portion 54 facing the winding portion 21 is an arc surface that follows the outer shape of the winding portion 21. Of the arc surface of the side portion 54, the end in the X1 direction functions as a second engagement portion 55 that engages with the first engagement portion 45 of the spacer 4. The first engagement portion 45 is an arc-shaped bulge formed at the end of the spacer 4 in the Y1 direction. The first engagement portion 45 and the second engagement portion 55 are joined together, for example, with an adhesive or the like.

[0068] The side portion 54 has a function of determining the relative positions of the spacer 4 and the spacer 5. In addition, the side portion 54 has a function of preventing the composite material constituting the side core portion 323 from contacting the winding portion 21 when the magnetic core 3 is molded from the composite material.

[0069] <Reactor placement> An example of an arrangement state of the reactor 1 of the embodiment 1 will be described with reference to Fig. 6. In Fig. 6, the first convex portions 41, 51 and the second convex portions 43, 53 of the reactor 1 are illustrated larger than their actual dimensions for ease of understanding.

[0070] 6, reactor 1 is disposed in case 9. Case 9 in this example has a long and narrow space 90 sandwiched between two plates. Long and narrow space 90 has mounting surfaces 91 and 92 facing each other.

[0071] The first convex portion 41 of the spacer 4 and the first convex portion 51 of the spacer 5 are in contact with the mounting surface 91. The first convex portions 41, 51 hold the winding portion 21 and the outer core portion 32 at a position away from the mounting surface 91. In addition, in the vicinity of the first convex portion 41, the first convex portion 41 and the first overhanging portion 40 ensure a sufficient creeping distance from the mounting surface 91 to the end core portion 321, and in the vicinity of the first convex portion 51, the first convex portion 51 and the first overhanging portion 50 ensure a sufficient creeping distance from the mounting surface 91 to the end core portion 322. Therefore, the current flowing through the winding portion 21 of the reactor 1 is prevented from causing a ground fault to the mounting surface 91.

[0072] The second convex portion 43 of the spacer 4 and the second convex portion 53 of the spacer 5 are in contact with the mounting surface 92. The second convex portions 43, 53 hold the winding portion 21 and the outer core portion 32 at a position away from the mounting surface 92. In addition, in the vicinity of the second convex portion 43, the second convex portion 43 and the second overhang portion 42 ensure a sufficient creeping distance from the mounting surface 92 to the end core portion 321, and in the vicinity of the second convex portion 53, the second convex portion 53 and the second overhang portion 52 ensure a sufficient creeping distance from the mounting surface 92 to the end core portion 322. Therefore, the current flowing through the winding portion 21 of the reactor 1 is prevented from causing a ground fault to the mounting surface 92.

[0073] In this example, in the direction toward mounting surface 91, none of the outer circumferential surface of winding portion 21, the outer circumferential surface of outer core portion 32, and end 23 of winding portion 21 protrudes from first overhanging portions 40, 50. In addition, in the direction toward mounting surface 92, none of the outer circumferential surface of winding portion 21, the outer circumferential surface of outer core portion 32, and end 22 of winding portion 21 protrudes from second overhanging portions 42, 52. Therefore, it is easy to arrange reactor 1 so as to fit it into narrow space 90.

[0074] Although not shown, insulating members may be disposed between winding portion 21 and mounting surface 91, and between winding portion 21 and mounting surface 92. The insulating members have a function of dissipating heat from reactor 1 to case 9. The insulating member is, for example, an insulating sheet or insulating grease.

[0075] <Embodiment 2> <Converter / power conversion device> The reactor 1 according to the above embodiment can be used for applications that satisfy the following energization conditions. The energization conditions include, for example, a maximum DC current of about 100 A to 1000 A, an average voltage of about 100 V to 1000 V, and an operating frequency of about 5 kHz to 100 kHz. The reactor 1 according to the embodiment is typically used as a component of a converter mounted on a vehicle such as an electric vehicle or a hybrid vehicle, or as a component of a power conversion device including this converter.

[0076] 7, a vehicle 1200 such as a hybrid vehicle or an electric vehicle includes a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and a motor 1220 that is driven by power supplied from the main battery 1210 and used for traveling. The motor 1220 is typically a three-phase AC motor, which drives wheels 1250 during traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, the vehicle 1200 includes an engine 1300 in addition to the motor 1220. In FIG. 7, the charging point of the vehicle 1200 is an inlet, but a form including a plug may also be used.

[0077] The power conversion device 1100 includes a converter 1110 connected to a main battery 1210, and an inverter 1120 connected to the converter 1110 and performing mutual conversion between direct current and alternating current. The converter 1110 shown in this example boosts the input voltage of the main battery 1210, which is about 200V to 300V, to about 400V to 700V when the vehicle 1200 is running, and supplies power to the inverter 1120. During regeneration, the converter 1110 lowers the input voltage output from the motor 1220 via the inverter 1120 to a direct current voltage suitable for the main battery 1210, and charges the main battery 1210. The input voltage is a direct current voltage. When the vehicle 1200 is running, the inverter 1120 converts the DC boosted by the converter 1110 into a predetermined AC and supplies it to the motor 1220. During regeneration, the inverter 1120 converts the AC output from the motor 1220 into DC and outputs it to the converter 1110.

[0078] As shown in FIG. 8, 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 repeatedly switching on and off. The conversion of the input voltage means stepping up and down the voltage here. The switching elements 1111 are power devices such as field effect transistors and insulated gate bipolar transistors. The reactor 1115 utilizes the properties of a coil that prevents changes in the current flowing through the circuit, and has a function of smoothing out changes when the current increases or decreases due to switching operations. The reactor 1 according to the embodiment is included as the reactor 1115.

[0079] In addition to the converter 1110, the vehicle 1200 includes a converter 1150 for a power supply device connected to the main battery 1210, and a converter 1160 for an auxiliary power supply connected to a sub-battery 1230 serving as a power source for the auxiliary devices 1240 and the main battery 1210 to convert the high voltage of the main battery 1210 to a low voltage. The converter 1110 typically performs DC-DC conversion, while the converter 1150 for a power supply device and the converter 1160 for an auxiliary power supply perform AC-DC conversion. Some of the converters 1150 for a power supply device perform DC-DC conversion. The reactors of the converter 1150 for a power supply device and the converter 1160 for an auxiliary power supply may have the same configuration as the reactor 1 according to the embodiment, and may be appropriately changed in size, shape, and the like. The reactor 1 according to the embodiment may also be used as a converter that converts input power and that performs only step-up or step-down. [Explanation of symbols]

[0080] 1 Reactor 2 Coil 21 Winding section 21s Inner surface 22,23 End 3. Magnetic core 31 Inner core part 32 Outer core part 33 Front page 33c Recess 33s flat part 34 Second side 34c Recess 34s flat part 321, 322 End core section 323 Side core part 4,5 Spacer 4h,5h through hole 40,50 First eave 41,51 First convex part 42,52 Second eave part 43,53 Second convex part 45 First engaging part 54 Side section 55 Second engaging part 41e End face 41s Side wall 9 Cases 90 space 91,92 Mounting surface 1100 Power conversion device 1110 Converter 1111 Switching element 1112 Drive circuit 1115 Reactor 1120 Inverter 1150 Power Supply Converter 1160 Auxiliary power converter 1200 vehicles 1210 Main Battery 1220 Motor 1230 Sub Battery 1240 Auxiliary Equipment 1250 wheels 1300 Engine

Claims

1. A coil having a winding portion; a magnetic core having an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion; a spacer disposed between an end face of the winding portion and the outer core portion, the outer core portion has a first surface perpendicular to a first direction, the first direction being a direction intersecting an axis of the winding portion, The spacer is A first overhanging portion extending along the first surface and overlapping the first surface; a first protrusion protruding in the first direction, The first convex portion protrudes in the first direction further than the outer core portion and the winding portion. Reactor.

2. the first surface includes a planar portion and a recess; The first overhanging portion is disposed in the recessed portion, The reactor according to claim 1 , wherein the flat portion and a surface of the first overhanging portion facing the first direction are flush with each other.

3. 3. The reactor according to claim 1, wherein a creepage distance from the first convex portion along a surface of the spacer to the outer core portion is 4 mm or more.

4. The reactor according to claim 1 or 2, wherein a surface of the first overhanging portion facing the first direction and a surface of the winding portion facing the first direction are flush with each other.

5. The inner core portion is made of a composite material in which soft magnetic powder is dispersed in a resin, The reactor according to claim 1 , wherein the inner core portion is in contact with an inner circumferential surface of the winding portion.

6. The outer core portion is made of the composite material, The reactor according to claim 5 , wherein the inner core portion and the outer core portion are integral with each other.

7. The reactor according to claim 1 or 2, wherein the winding portion has a flat shape that is thinned in the first direction.

8. The outer core portion has a second surface facing a second direction opposite to the first direction, The spacer is A second overhanging portion extending along the second surface and overlapping the second surface; a second protrusion protruding in the second direction, The reactor according to claim 1 , wherein the second convex portion protrudes in the second direction further than the outer core portion and the winding portion.

9. A reactor comprising the reactor according to claim 1 or 2. converter.

10. A converter comprising: Power conversion equipment.

Images