Reactor, converter, and power conversion device

Abstract

To provide a compact reactor excellent in heat dissipation.SOLUTION: The reactor is provided with a coil and a magnetic core having: an inner-side core part which is disposed inside the coil; and an outer-side core part which is disposed outside the coil. The coil has a winding which is wound to be along the outer peripheral surface of the inner-side core part. The outer peripheral shape of the coil, viewed in a first direction along the axis of the coil, is rectangular. The outer peripheral surface of the coil has a first coil surface and a second coil surface which are opposite to each other and are along each of the long sides of the outer peripheral shape of the coil. The first coil surface and the second coil surface are exposed from the outer-side core part. At least the outer peripheral region of the inner-side core part is constituted of a molding of composite material, and the outer peripheral surface of the inner-side core part has a plurality of groove portions arranged in the direction along the axis of the inner-side core part. The winding in respective turns of the coil is disposed in the plurality of groove portions.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] The reactor of Patent Document 1 includes a coil and a magnetic core. The coil has a pair of winding portions formed by winding a wire in a spiral shape. Each winding portion has a rectangular cylindrical shape. The magnetic core has a pair of inner core portions and a pair of outer core portions. Each inner core portion is disposed inside each winding portion. Each inner core portion has a rectangular column shape. Each outer core portion is disposed outside both winding portions. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2013-219318 A Summary of the Invention [Problem to be solved by the invention]

[0004] The reactor of Patent Document 1 is manufactured as follows. A pair of winding parts is prepared. Each inner core part is inserted into each winding part. Both inner core parts and both outer core parts are fixed. To insert each inner core part into each winding part, a gap is provided between the inner peripheral surface of each winding part and the outer peripheral surface of each inner core part. The provision of the gap makes it difficult to miniaturize the reactor and also difficult to improve heat dissipation.

[0005] An object of the present disclosure is to provide a reactor that is small and has excellent heat dissipation properties. [Means for solving the problem]

[0006] The reactor of the present disclosure includes: A coil and a magnetic core having an inner core portion disposed inside the coil and an outer core portion disposed outside the coil, The coil has a winding wound along an outer circumferential surface of the inner core portion, The outer circumferential shape of the coil is rectangular when viewed from a first direction along the axis of the coil, the outer circumferential surface of the coil has a first coil surface and a second coil surface that are aligned along each of the long sides of the outer circumferential shape of the coil and face each other, the first coil surface and the second coil surface are exposed from the outer core portion, At least an outer circumferential region of the inner core portion is formed of a composite material molding, an outer circumferential surface of the inner core portion has a plurality of grooves aligned in a direction along the axis of the inner core portion; The windings in each turn of the coil are disposed in each of the plurality of grooves. Effect of the Invention

[0007] The reactor of the present disclosure is small and has excellent heat dissipation properties. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a first perspective view showing the reactor of the first embodiment. FIG. [Diagram 2] FIG. 2 is a second perspective view showing the reactor of the first embodiment. [Diagram 3] FIG. 3 is a cross-sectional view taken along line III-III of FIG. [Figure 4] FIG. 4 is an enlarged view of area A in FIG. [Diagram 5] FIG. 5 is a schematic perspective view showing a magnetic core provided in the reactor of the first embodiment. [Figure 6] FIG. 6 is a perspective view showing a spacer provided in the reactor of the first embodiment. [Figure 7] FIG. 7 is a first perspective view showing the reactor of the second embodiment. [Figure 8]FIG. 8 is a second perspective view showing the reactor of the second embodiment. [Figure 9] FIG. 9 is a perspective view showing a magnetic core provided in the reactor of the second embodiment. [Figure 10] FIG. 10 is a perspective view showing a spacer provided in the reactor of the second embodiment. [Figure 11] FIG. 11 is an enlarged view showing a groove and a winding in the reactor of the third embodiment. [Figure 12] FIG. 12 is an enlarged view showing a groove and a winding in the reactor of the fourth embodiment. [Figure 13] FIG. 13 is a schematic diagram showing a power supply system of a hybrid vehicle. [Figure 14] FIG. 14 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) A reactor according to an embodiment of the present disclosure includes: A coil and a magnetic core having an inner core portion disposed inside the coil and an outer core portion disposed outside the coil, The coil has a winding wound along an outer circumferential surface of the inner core portion, The outer circumferential shape of the coil is rectangular when viewed from a first direction along the axis of the coil, the outer circumferential surface of the coil has a first coil surface and a second coil surface that are aligned along each of the long sides of the outer circumferential shape of the coil and face each other, the first coil surface and the second coil surface are exposed from the outer core portion, At least an outer circumferential region of the inner core portion is formed of a composite material molding, an outer circumferential surface of the inner core portion has a plurality of grooves aligned in a direction along the axis of the inner core portion; The windings in each turn of the coil are disposed in each of the plurality of grooves.

[0011] In the reactor of (1), the winding in each turn is disposed in each groove on the outer circumferential surface of the inner core portion, so that the gap between the inner core portion and the coil is substantially 0 (zero). Therefore, the reactor of (1) is smaller than a case where a gap is provided between the inner core portion and the coil. In addition, the reactor of (1) easily transmits the heat of the coil to the magnetic core compared to a case where a gap is provided between the inner core portion and the coil. Therefore, in the reactor of (1), the heat of the coil can be directly transmitted to the installation target from the first coil surface or the second coil surface exposed from the outer core portion, and the heat can be indirectly transmitted to the installation target from the magnetic core by contacting the outer core portion with the installation target. Therefore, the reactor of (1) has excellent heat dissipation properties. In addition, in the reactor of (1), the height of the coil can be reduced because the outer circumferential shape of the coil is rectangular. In this specification, the gap being substantially zero includes not only the case where the gap is zero, but also the case where a gap is provided locally to the extent that the heat dissipation effect is not hindered.

[0012] (2) In the reactor described in (1) above, the inner core portion and the outer core portion are an integral molded body, The inner core portion and the outer core portion may all be formed from a molded body of the composite material.

[0013] In the reactor of (2) above, the inner core portion and the outer core portion are configured as an integral molded body of a composite material, so that the inner core portion and the outer core portion can be manufactured together. Therefore, the manufacturing process of the reactor of (2) above can be simplified compared to a case in which the inner core portion and the outer core portion are manufactured separately and then combined with each other. Therefore, the reactor of (2) above has excellent productivity.

[0014] (3) In the reactor of (2) above, the outer core portion has a first end core portion facing a first end surface of the coil and a second end core portion facing a second end surface of the coil, At least one of the first end core portion and the second end core portion may have a gate mark.

[0015] The reactor (3) above is manufactured as follows: The coil is placed in a mold. The raw material of the composite compact is filled into the mold, including the inside of the coil, through one or more gates. The raw material is a fluid material in which soft magnetic powder is dispersed in unsolidified resin. The resin is solidified.

[0016] When the resin has solidified, an attachment having a portion corresponding to the gate is connected to the magnetic core. In addition to the portion corresponding to the gate, the attachment may have a portion corresponding to the sprue, and may also have a portion corresponding to the runner. The attachment is removed from the magnetic core. The attachment can be removed, for example, by breaking it off. A gate mark in the form of a protrusion or ridge protruding from the surface remains on the surface of the magnetic core from which the attachment has been removed.

[0017] By providing a gate in the die facing the molding space of the end core portion, the raw material can be easily poured into the inside of the coil, making it easy to mold the entire magnetic core.

[0018] By manufacturing the reactor of (3) above as described above, it is difficult for the composite material molded body to be disposed between the turns, and for the composite material molded body to protrude outside the coil from between the turns.

[0019] (4) In the reactor of (3) above, the coil has a first winding portion and a second winding portion arranged in parallel with each other, The inner core portion may have a first inner core portion disposed inside the first winding portion, and a second inner core portion disposed inside the second winding portion.

[0020] In the reactor of (4) above, the winding constituting each turn of the first winding portion is arranged in each of a plurality of grooves in the outer peripheral surface of the first inner core portion, and the winding constituting each turn of the second winding portion is arranged in each of a plurality of grooves in the outer peripheral surface of the second inner core portion. Therefore, the gap between the first winding portion and the first inner core portion is substantially zero, and the gap between the second winding portion and the second inner core portion is substantially zero. Therefore, the reactor of (4) above is small. In addition, the reactor of (4) above has excellent heat dissipation properties because it is easy to transfer heat from the first winding portion to the first inner core portion and easy to transfer heat from the second winding portion to the second inner core portion.

[0021] (5) In the reactor of (3) above, The number of the coils is one, The outer core portion may further include at least one side core portion arranged in parallel with the inner core portion.

[0022] The reactor (5) above is small and has excellent heat dissipation properties.

[0023] (6) A converter according to an embodiment of the present disclosure includes: The reactor is any one of the reactors described in (1) to (5) above.

[0024] The converter has excellent performance since it includes the reactor.

[0025] (7) A power conversion device according to an embodiment of the present disclosure, Equipped with the converter described above in (6).

[0026] The power conversion device has excellent performance since it includes the converter.

[0027] Details of the embodiments of the present disclosure DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present disclosure will now be described in detail with reference to the accompanying drawings, in which like reference numerals indicate like objects.

[0028] First Embodiment [Reactor] A reactor 1 of the first embodiment will be described with reference to Figs. 1 to 6. As shown in Fig. 1, the reactor 1 includes a coil 2 and a magnetic core 3. The coil 2 has a first winding 20f and a second winding 20s wound in a spiral shape. The magnetic core 3 has an inner core portion 31 and an outer core portion 32 shown in Fig. 5. The inner core portion 31 shown in Fig. 5 is disposed inside the coil 2 shown in Figs. 1 and 2. The outer core portion 32 is disposed outside the coil 2 as shown in Figs. 1 and 2. One of the features of the reactor 1 of this embodiment is that it satisfies the following requirements (a) to (c). (a) The outer peripheral shape of coil 2 is rectangular when viewed from a first direction along the axis of coil 2. The outer peripheral surface of coil 2 has first coil surface 211 and second coil surface 212 that are along each of the long sides of the outer peripheral shape of coil 2 and face each other, and first coil surface 211 and second coil surface 212 are exposed from outer core portion 32. (b) At least the outer circumferential region of the inner core portion 31 is made of a molded body of a composite material. (c) The outer peripheral surface of the inner core portion 31 has a plurality of grooves 31a aligned in a direction along the axis of the inner core portion 31. The first winding 20f and the second winding 20s in each turn of the coil 2 are disposed in each of the plurality of grooves 31a.

[0029] In the following description, the X1 direction, X2 direction, Y1 direction, Y2 direction, Z1 direction, and Z2 direction defined as follows will be used. The X1 direction is a direction from the second end face to the first end face of the coil 2 along the axis of the coil 2. The X2 direction is a direction opposite to the X1 direction. The Y1 direction is a direction along the long side of the rectangular outer periphery of the coil 2. The Y2 direction is a direction opposite to the Y1 direction. The Z1 direction is a direction perpendicular to both the X1 direction and the Y1 direction, and is a direction from the second coil surface 212 to the first coil surface 211 of the coil 2. The Z2 direction is the opposite direction to the Z1 direction.

[0030] [coil] As shown in FIG. 1 and FIG. 2, the coil 2 of this example has a first winding portion 21f and a second winding portion 21s. The first winding portion 21f has a first winding 20f wound so as to follow the outer circumferential surface of the first inner core portion 31f shown in FIG. 5. The second winding portion 21s has a second winding 20s wound so as to follow the outer circumferential surface of the second inner core portion 31s shown in FIG. 5. The first winding 20f and the second winding 20s are wound in a spiral shape. In this example, the first winding 20f and the second winding 20s are not connected. That is, the first winding portion 21f and the second winding portion 21s are members independent of each other. Unlike this example, the first winding 20f and the second winding 20s may be a continuous winding. The first winding portion 21f and the second winding portion 21s have the same configuration. The following description will be mainly given of the first winding portion 21f.

[0031] The first winding portion 21f has a rectangular cylindrical shape. The rectangular cylindrical shape of the first winding portion 21f makes it easier to increase the contact area between the first winding portion 21f and a planar installation target, compared to when the first winding portion 21f has a circular cylindrical shape with the same cross-sectional area. Therefore, the reactor 1 easily transfers heat from the coil 2 to an installation target (not shown). The installation target is, for example, an air-cooled or water-cooled cooling base. The four corners of the first winding portion 21f are rounded. The outer peripheral shape of the first winding portion 21f seen from the first direction is rectangular. The first direction is the X1 direction. The first end surface and the second end surface of the first winding portion 21f have a rectangular frame shape. In the first winding portion 21f, the length along the Y1 direction is longer than the length along the Z1 direction.

[0032] The outer peripheral surface of the first winding portion 21f has a first coil surface 211 and a second coil surface 212 facing each other. The first coil surface 211 and the second coil surface 212 are along the long side of the rectangular outer peripheral shape of the first winding portion 21f. The first coil surface 211 and the second coil surface 212 are flat surfaces. In the first winding portion 21f, the length along the Y1 direction is longer than the length along the Z1 direction. Therefore, for example, since the first coil surface 211 and the second coil surface 212 are wide surfaces, it is easy to transfer heat of the coil 2 to the installation target by bringing the first coil surface 211 or the second coil surface 212 into contact with the installation target.

[0033] As shown in FIG. 1 and FIG. 2, the first winding 20f is a series of windings without joints. The first winding 20f is a known winding. The first winding 20f of this example uses a coated rectangular wire. The conductor wire of the coated rectangular wire is made of a rectangular copper wire. The insulating coating of the coated rectangular wire is made of enamel. The first winding portion 21f of this example is formed by edgewise winding the coated rectangular wire. The first winding portion 21f has substantially no gaps between the turns. Unlike this example, the first winding portion 21f may be formed by flatwise winding the coated rectangular wire. The first winding 20f may be a round wire described in embodiment 4 with reference to FIG. 12. Although not shown, the first winding 20f may be a rectangular wire with a square cross section, a Litz wire, or the like.

[0034] As shown in FIG. 3 and FIG. 4, the first winding 20f is disposed in a groove 31a, which will be described later. A portion of the first winding 20f constituting the inner circumferential surface of the first winding portion 21f is disposed in the groove 31a and is in direct contact with the groove 31a. In the first winding 20f constituting each turn, a portion of the first winding portion 21f constituting the inner circumferential surface is disposed in the groove 31a over the entire length. By disposing the first winding portion 21f in the groove 31a, the gap between the first winding portion 21f and the first inner core portion 31f is substantially 0 (zero). Therefore, the reactor 1 can be made compact. In addition, the reactor 1 easily transmits heat of the first winding portion 21f to the first inner core portion 31f. Therefore, the reactor 1 can directly transmit the heat of the coil 2 to the installation target from the first coil surface 211 or the second coil surface 212 exposed from the outer core portion 32, and indirectly transmit the heat to the installation target from the magnetic core 3 by bringing the outer core portion 32 into contact with the installation target. Therefore, reactor 1 has excellent heat dissipation properties.

[0035] In this example, the first end 201 of the first winding 20f is drawn out from the first end surface of the first winding portion 21f in the X1 direction along the X1 direction. The second end 202 of the first winding 20f is drawn out from the second end surface of the first winding portion 21f in the X2 direction along the X2 direction. Specifically, the first end 201 and the second end 202 are drawn out by flatwise bending the first winding 20f in the turns constituting the first end surface and the second end surface of the first winding portion 21f. More specifically, the first end 201 of the first winding 20f is drawn out such that the surface of the first end 201 of the first winding 20f facing the Z1 direction is substantially flush with the first coil surface 211. Moreover, the second end 202 of the first winding 20f is drawn out such that the surface of the second end 202 of the first winding 20f facing the Z2 direction is substantially flush with the second coil surface 212. In this specification, "two surfaces are substantially flush" means that the flatness of the two surfaces is 0.4 mm or less. The flatness of the two surfaces may be 0.2 mm or less, 0.1 mm or less, or 0.05 mm or less. The flatness here is in accordance with JIS B 0621:1984, Definition and indication of geometric deviation.

[0036] In this example, the first end 201 of the second winding 20s is drawn out from the first end surface of the second winding portion 21s in the X1 direction along the X1 direction. The second end 202 of the second winding 20s is drawn out from the second end surface of the second winding portion 21s in the X2 direction along the X2 direction. Specifically, the first end 201 and the second end 202 are drawn out by flatwise bending the second winding 20s in the turns constituting the first end surface and the second end surface of the second winding portion 21s. More specifically, the first end 201 of the second winding 20s is drawn out such that the surface of the first end 201 of the second winding 20s facing the Z2 direction is substantially flush with the second coil surface 212. Moreover, the second end 202 of the second winding 20s is drawn out such that the surface of the second end 202 of the second winding 20s facing the Z1 direction is substantially flush with the first coil surface 211.

[0037] Although not shown, the insulating coating of the first end 201 and the second end 202 is stripped off to expose the conductor wire. A terminal member (not shown) is connected to the exposed conductor wire. An external device (not shown) is connected to the coil 2 via this terminal member. The external device is, for example, a power source that supplies power to the coil 2.

[0038] [Magnetic core] The magnetic core 3 forms a closed magnetic circuit by the inner core portion 31 and the outer core portion 32 shown in Fig. 5. As shown in Fig. 5, the planar shape of the magnetic core 3 of this example when viewed from the Z1 direction is a rectangular ring shape.

[0039] (Inner core part) The inner core portion 31 of this example has a first inner core portion 31f and a second inner core portion 31s. The first inner core portion 31f is disposed inside the first wound portion 21f shown in Figs. 1 and 2. The second inner core portion 31s is disposed inside the second wound portion 21s shown in Figs. 1 and 2. The first inner core portion 31f and the second inner core portion 31s have the same configuration. The following description will mainly focus on the first inner core portion 31f.

[0040] The first inner core portion 31f is aligned along the axis of the first winding portion 21f. In this example, both ends of the portion of the magnetic core 3 aligned along the axis of the first winding portion 21f protrude from the first end face and the second end face of the first winding portion 21f to the outside of the first winding portion 21f. The portions protruding from the first winding portion 21f are also part of the first inner core portion 31f.

[0041] The shape of the first inner core portion 31f corresponds to the inner peripheral contour shape of the coil 2. The shape of the first inner core portion 31f is a quadrangular prism. Each of the four corners of the first inner core portion 31f is rounded so as to fit along each of the four corners of the inner peripheral surface of the coil 2. The outer peripheral shape of the first inner core portion 31f seen from the first direction is rectangular. In the first inner core portion 31f, the length along the Y1 direction is longer than the length along the Z1 direction.

[0042] As shown in FIG. 3 and FIG. 4, the outer peripheral surface of the first inner core portion 31f has a plurality of grooves 31a arranged in a direction along the axis of the first inner core portion 31f. The plurality of grooves 31a are formed according to the inner peripheral surface of the first wound portion 21f when the first inner core portion 31f is formed. Having a plurality of grooves 31a means that the grooves 31a are independent of each other along the X1 direction when focusing on only a certain surface of the outer peripheral surface of the first inner core portion 31f. The outer peripheral surface of the first inner core portion 31f in this example has one spiral groove provided coaxially with the first inner core portion 31f. If the entire circumference of the outer peripheral surface of the first inner core portion 31f is focused on, the spiral groove is continuous, so the number of spiral grooves is one. In other words, the spiral groove is a continuous groove when viewed along the longitudinal direction of the groove, so the number of spiral grooves is one. In this spiral groove, when focusing on only a certain surface of the outer circumferential surface of the first inner core portion 31f, the groove portions 31a are independent of each other along the X1 direction, and therefore this is included in having a plurality of groove portions 31a.

[0043] As shown in FIG. 4, the width of each groove 31a is the same as the thickness of the first winding 20f, which is a coated rectangular wire in this embodiment. The width of the groove 31a is a length along a direction perpendicular to both the extension direction of the groove 31a and the depth direction of the groove 31a. Since the width of each groove 31a is substantially the same as the thickness of the first winding 20f, the contact area between the first winding 20f arranged in each groove 31a and the first inner core portion 31f tends to be large. Therefore, the heat of the first winding 20f is easily transferred to the first inner core portion 31f. Therefore, the reactor 1 has excellent heat dissipation properties.

[0044] As shown in FIG. 5, the outer peripheral surface of the first inner core portion 31f may have a plurality of recesses 31b recessed relative to the locations where the plurality of grooves 31a are provided. Specifically, each recess 31b is recessed relative to the bottom of the groove 31a. The recesses 31b are recesses formed according to the guide portion 43 of the spacer 4 described later. By having the recesses 31b, the connection between the spacer 4 and the first inner core portion 31f can be strengthened. The shape of the recesses 31b in this example is C-shaped. The recesses 31b are provided on the surface of the first inner core portion 31f facing the Y1 direction or the Y2 direction. The recesses 31b in this example are provided near the four corners of the first inner core portion 31f when the first inner core portion 31f is viewed from the Z1 direction. The number of recesses 31b in this example is four for the first inner core portion 31f. In other words, since the second inner core portion 31s also has four recesses 31b, the total number of recesses 31b provided in the magnetic core 3 is eight. The shape, arrangement location and number of the recesses 31b are not limited to this example and can be selected appropriately.

[0045] At least the outer peripheral region of the first inner core portion 31f is made of a composite material molded body. The outer peripheral region is a region of the first inner core portion 31f from the outer peripheral surface facing the inner peripheral surface of the first winding portion 21f to a predetermined depth. The predetermined depth is the same depth as the depth of the groove portion 31a described above. The composite material molded body is a molded body in which soft magnetic powder is dispersed in resin. The center region of the first inner core portion 31f may be made of a composite material molded body or a powder compact. The center region of the first inner core portion 31f is a region inside the outer peripheral region. The powder compact is a molded body formed by compressing and molding soft magnetic powder. In this example, the outer peripheral region and center region of the first inner core portion 31f, i.e., the entire region of the first inner core portion 31f, is made of a composite material molded body.

[0046] The composite material compact allows easy adjustment of the content ratio of the soft magnetic powder in the resin. Therefore, the magnetic properties of the composite material compact are easy to adjust. Furthermore, the composite material compact can be easily formed into a complex shape compared to a pressed powder compact. The soft magnetic powder content in the composite material compact is, for example, 20% by volume or more and 80% by volume or less. The resin content in the composite material compact is, for example, 20% by volume or more and 80% by volume or less. These content ratios are relative to the volume of the composite material compact taken as 100%.

[0047] The powder compact can have a higher ratio of soft magnetic powder in the magnetic core 3 than the composite material compact. Therefore, the powder compact can have improved magnetic properties. Examples of magnetic properties include relative permeability and saturation magnetic flux density. Furthermore, the powder compact has a smaller amount of resin and a larger amount of soft magnetic powder than the composite material compact, and therefore has excellent heat dissipation properties. The content of the soft magnetic powder in the powder compact is, for example, 85% by volume or more and 99% by volume or less. This content is the ratio relative to the volume of the powder compact being 100%.

[0048] The particles constituting the soft magnetic powder are, for example, soft magnetic metal particles, coated particles, or soft magnetic nonmetal particles. The coated particles include a soft magnetic metal particle and an insulating coating provided on the outer periphery of the soft magnetic metal particle. 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 is, for example, a phosphate. The soft magnetic nonmetal is, for example, a ferrite.

[0049] The resin of the composite material molded body is, for example, a thermosetting resin or a thermoplastic resin. The thermosetting resin is, for example, an epoxy resin, a phenolic resin, a silicone resin, or a urethane resin. The thermoplastic resin is, for example, a polyphenylene sulfide (PPS) resin, a polyamide (PA) resin, a liquid crystal polymer (LCP), a polyimide resin, or a fluororesin. The PA resin is, for example, nylon 6, nylon 66, or nylon 9T.

[0050] The composite material compact may contain a filler, which is a non-magnetic powder such as alumina or silica, and which contributes to improving heat dissipation and electrical insulation.

[0051] The content of soft magnetic powder in the composite material compact and the content of soft magnetic powder in the powder compact are considered to be equivalent to the area proportion of the soft magnetic powder in the cross section of the compact. The content of soft magnetic powder in the compact is determined as follows. The cross section of the compact is observed with a SEM (scanning electron microscope) to obtain an observation image. The cross section of the compact may be any cross section. The magnification of the SEM is 200 times or more and 500 times or less. At least 10 observation images are obtained. The total cross section is 0.1 cm2. 2 That is all. One observation image may be acquired per cross section, or multiple observation images may be acquired per cross section. Each acquired observation image is subjected to image processing to extract particle contours. Image processing includes, for example, binarization processing. The area ratio of soft magnetic particles in each observation image is calculated, and the average value of the area ratios is obtained. The average value is regarded as the content ratio of soft magnetic powder.

[0052] (Outer core part) The outer core portion 32 of this example has a first end core portion 34f and a second end core portion 34s. The first end core portion 34f faces first end faces of the first wound portion 21f and the second wound portion 21s. Facing means facing. The first end core portion 34f is connected to first ends of the first inner core portion 31f and the second inner core portion 31s. The surface of the first end core portion 34f facing the X2 direction is in direct contact with the surface of the base portion 42a of the first spacer 41f described below facing the X1 direction. The second end core portion 34s faces second end faces of the first wound portion 21f and the second wound portion 21s. The second end core portion 34s is connected to second ends of the first inner core portion 31f and the second inner core portion 31s. The surface of the second end core portion 34s facing the X1 direction is in direct contact with the surface of the base portion 42a of the second spacer 41s facing the X2 direction. The first end core portion 34f and the second end core portion 34s have the same configuration, and the following description will mainly focus on the first end core portion 34f.

[0053] The first end core portion 34f has a quadrangular prism shape. When viewed from the X1 direction, the outer peripheral shape of the first end core portion 34f is rectangular. In the first end core portion 34f, the length along the Y1 direction is longer than the length along the Z1 direction. The length along the Y1 direction of the first end core portion 34f is the same as the length along the Y1 direction of the first winding portion 21f and the second winding portion 21s.

[0054] The outer peripheral surface of first end core portion 34f has first core surface 341 and second core surface 342 facing each other. First core surface 341 and second core surface 342 are along the long side of the rectangular outer peripheral shape. First core surface 341 is substantially flush with first coil surface 211, and second core surface 342 is substantially flush with second coil surface 212. Therefore, the maximum difference between first core surface 341 and first coil surface 211 in the Z1 direction and the maximum difference between second core surface 342 and second coil surface 212 in the Z2 direction can be reduced, and both maximum differences can be brought close to 0 (zero).

[0055] As described above, since the first end 201 of the first winding 20f, the second end 202 of the second winding 20s, and the first coil surface 211 are substantially flush with each other, the first end 201 of the first winding 20f, the second end 202 of the second winding 20s, and the first core surface 341 are substantially flush with each other. Since the second end 202 of the first winding 20f, the first end 201 of the second winding 20s, and the second coil surface 212 are substantially flush with each other, the second end 202 of the first winding 20f, the first end 201 of the second winding 20s, and the second core surface 342 are substantially flush with each other. Therefore, when the reactor 1 is installed on a planar installation target, both first coil surfaces 211 and both first core surfaces 341 can be brought into contact with the installation target without the first end 201 of the first winding 20f and the second end 202 of the second winding 20s interfering with the installation target. Alternatively, when the reactor 1 is installed on a planar installation target, both second coil surfaces 212 and both second core surfaces 342 can be brought into contact with the installation target without the second end 202 of the first winding 20f and the first end 201 of the second winding 20s interfering with the installation target. Thus, the reactor 1 can have a larger contact area between the reactor 1 and the installation target than the reactor X. The reactor X is a reactor in which only the first coil surface 211 is in contact with the installation target without both first core surfaces 341 being in contact with the installation target.

[0056] In particular, the first core surface 341 and the second core surface 342 are wide surfaces that run along the long sides of the rectangular outer periphery, and therefore the contact area with the installation object can be increased. In the reactor 1, not only the heat of the coil 2 but also the heat of the first end core portion 34f and the second end core portion 34s is more easily transferred to the installation object than in the reactor X. Therefore, the reactor 1 is easier to improve the heat dissipation performance than the reactor X.

[0057] In the reactor 1, the first core surface 341 and the first coil surface 211 are substantially flush with each other, and the second core surface 342 and the second coil surface 212 are substantially flush with each other, so that the first end surfaces of the coil 2 are covered by the first end core portion 34f in a wide area, and the second end surfaces are covered by the second end core portion 34s in a wide area. That is, the first end surfaces face the first end core portion 34f in a wide area, and the second end surfaces face the second end core portion 34s in a wide area. Therefore, the reactor 1 is more likely to reduce leakage magnetic flux from the vicinity of the first end surfaces and the vicinity of the second end surfaces than the reactor Y. That is, the reactor 1 is less likely to leak magnetic flux from the vicinity of the first end surfaces and the vicinity of the second end surfaces than the reactor Y. The reactor Y is a reactor in which both first end faces are partially exposed from the first end core portion 34f and not covered by the first end core portion 34f, and both second end faces are partially exposed from the second end core portion 34s and not covered by the second end core portion 34s. The reactor 1 can have both first coil faces 211 and both first core faces 341 in contact with the installation target, or both second coil faces 212 and both second core faces 342 in contact with the installation target. That is, the reactor 1 has many options for the face to be in contact with the installation target. Unlike this example, the first core face 341 does not have to be flush with the first coil face 211, and the second core face 342 does not have to be flush with the second coil face 212.

[0058] At least one of the first end core portion 34f and the second end core portion 34s may be formed of a molded body of the composite material described above, or may be formed of the powder compact described above. In this example, both the first end core portion 34f and the second end core portion 34s are formed of a molded body of the composite material.

[0059] In this example, the first inner core portion 31f, the second inner core portion 31s, the first end core portion 34f, and the second end core portion 34s are an integral molded body of a composite material. The first inner core portion 31f, the second inner core portion 31s, the first end core portion 34f, and the second end core portion 34s can be manufactured together. Therefore, the manufacturing process of the reactor 1 can be simplified compared to the case where the first inner core portion 31f, the second inner core portion 31s, the first end core portion 34f, and the second end core portion 34s are manufactured separately and then combined. Therefore, the reactor 1 has excellent productivity. At least one of the first end core portion 34f and the second end core portion 34s has a gate mark 35. In this example, both the first end core portion 34f and the second end core portion 34s have a gate mark 35. Unlike this example, only one of the first end core portion 34f and the second end core portion 34s may have a gate mark 35. The gate mark 35 will be described in detail in the manufacturing method section below.

[0060] In this example, the gate marks 35 of the first end core portion 34f are provided on the surface of the first end core portion 34f facing the X1 direction, as shown in FIG. 1. The gate marks 35 of the first end core portion 34f are provided at the end portion in the Z2 direction. The gate marks 35 of the second end core portion 34s are provided on the surface of the second end core portion 34s facing the X2 direction, as shown in FIG. 2. The gate marks 35 of the second end core portion 34s are provided at the end portion in the Z2 direction. The shape and position of each gate mark are not particularly important. The number of gate marks of each of the first end core portion 34f and the second end core portion 34s may be two or more, that is, the total number of gate marks provided on the magnetic core 3 may be four or more.

[0061] [Spacer] The reactor 1 of this example further includes a spacer 4. The spacer 4 positions the first winding portion 21f and the second winding portion 21s relative to each other. As shown in FIG. 6, the spacer 4 of this example is composed of two members, a first spacer 41f and a second spacer 41s. The first spacer 41f is disposed between the first end faces of the first winding portion 21f and the second winding portion 21s and the first end core portion 34f. The second spacer 41s is disposed between the second end faces of the first winding portion 21f and the second winding portion 21s and the second end core portion 34s. The first spacer 41f and the second spacer 41s have the same configuration. The following description will mainly focus on the first spacer 41f.

[0062] The first spacer 41f includes a base 42a and a plurality of guide portions 43. The base 42a is a main portion of the first spacer 41f and is configured in a B shape when viewed from the X1 direction. The outer peripheral shape of the base 42a when viewed from the X1 direction is rectangular. The length of the base 42a along the Y1 direction is longer than the length along the Z1 direction.

[0063] The outer peripheral surface of the base 42a has a first surface 421 and a second surface 422 that face each other. The first surface 421 and the second surface 422 are along the long sides of the rectangular outer peripheral shape of the base 42a. The first surface 421 and the second surface 422 are flat surfaces. The first surface 421 is substantially flush with both the first coil surfaces 211 and the first core surface 341. The second surface 422 is substantially flush with both the second coil surfaces 212 and the second core surface 342.

[0064] The base portion 42a has two through holes 44. Both through holes 44 penetrate so as to connect a surface of the base portion 42a facing the X1 direction with a surface facing the X2 direction. The first inner core portion 31f or the second inner core portion 31s penetrates each through hole 44. The shape of each through hole 44 as viewed from the X1 direction is rectangular except for a portion where a guide portion 43 described later is provided.

[0065] The base 42a has a first notch 451 and a second notch 452. The first notch 451 is provided at an end of the base 42a in the Y1 direction on the surface of the base 42a facing the Z1 direction. The first end 201 of the first winding 20f is fitted into the first notch 451. The size and shape of the first notch 451 correspond to the cross-sectional dimensions of the first winding 20f. The second notch 452 is provided at an end of the base 42a in the Y2 direction on the surface of the base 42a facing the Z2 direction. The first end 201 of the second winding 20s is fitted into the second notch 452. The size and shape of the second notch 452 correspond to the cross-sectional dimensions of the second winding 20s.

[0066] Each guide portion 43 is a portion for positioning the coil 2 with respect to the spacer 4 by fitting the first winding portion 21f and the second winding portion 21s to the outer periphery of the guide portion 43. The guide portion 43 protrudes in the X2 direction from the surface of the base portion 42a facing the X2 direction and extends to a part of the inner periphery of the through hole 44. There are two guide portions 43 for each through hole 44, totaling four. The guide portion 43 in this example is C-shaped. The C-shaped guide portions 43 are provided at both ends of each through hole 44 with their openings facing each other.

[0067] The first spacer 41f is made of an electrically insulating material. The first spacer 41f ensures electrical insulation between the first winding portion 21f and the second winding portion 21s and the outer core portion 32. Examples of the electrically insulating material include PPS resin, polytetrafluoroethylene (PTFE) resin, LCP, PA resin, polybutylene terephthalate (PBT) resin, and acrylonitrile butadiene styrene (ABS) resin. In addition, the material of the first spacer 41f may be a thermosetting resin such as an unsaturated polyester resin, an epoxy resin, a urethane resin, or a silicone resin. These resins may contain a filler. The filler is, for example, a non-magnetic powder such as alumina or silica.

[0068] [Manufacturing method] The reactor 1 of this example is manufactured by carrying out the following steps α to γ.

[0069] In step α, an assembly of the coil 2 and the spacer 4 is placed in a mold.

[0070] In step β, the raw material of the composite material compact is filled from the gate into the mold including the inside of the coil 2. The raw material is a fluid material in which soft magnetic powder is dispersed in unsolidified resin. In this example, two gates are provided. The first gate and the second gate are positioned so that when the raw material is filled from each of the first gate and the second gate, the coil 2 can be compressed so that the gap between each turn of the coil 2 is narrowed by the flow of the filled raw material into the inside of the coil 2. In this case, the filled raw material is unlikely to leak from the inside of the first winding portion 21f and the second winding portion 21s to the outside through the gap between the turns. The first gate is provided at a position facing the first end face of the coil 2, and the second gate is provided at a position facing the second end face of the coil 2. More specifically, the positions of the first gate and the second gate correspond to the first end core portion 34f and the second end core portion 34s, respectively. That is, the raw material filled from the first gate is filled into the first winding portion 21f and the second winding portion 21s from the openings at the first ends of the first winding portion 21f and the second winding portion 21s. The raw material filled from the second gate is filled into the first winding portion 21f and the second winding portion 21s from the openings at the second ends of the first winding portion 21f and the second winding portion 21s. The raw material filled from the first gate and the raw material filled from the second gate compress the coil 2 so that the distance between the turns becomes narrower.

[0071] When the raw material is filled from each gate in the above step β, the first spacer 41f and the second spacer 41s are pressed toward each other by the flow of the filled raw material into the inside of the coil 2. This pressing allows the first spacer 41f and the second spacer 41s to compress the coil 2 so that the gap between each turn of the coil 2 becomes narrower. Therefore, the filled raw material does not leak out from the inside of the first winding portion 21f and the second winding portion to the outside through the gap between the turns.

[0072] In step γ, the resin is solidified. When the resin is solidified, an attached portion having a portion corresponding to the gate is connected to the magnetic core 3. In addition to the portion corresponding to the gate, the attached portion may have a portion corresponding to the sprue, and may further have a portion corresponding to the runner. The attached portion is removed from the magnetic core 3. The attached portion can be removed, for example, by breaking the attached portion off. On the surface of the magnetic core 3 from which the attached portion has been removed, that is, on the surfaces of both the first end core portion 34f and the second end core portion 34s in this example, a gate mark 35 of a protrusion or ridge protruding from each surface remains. The fact that both the first end core portion 34f and the second end core portion 34s have the gate mark 35 as in this example means that the coil 2 is compressed so that the gap between the turns becomes narrower, as described above. Therefore, the raw material is less likely to leak from the inside of the coil 2 to the outside through the gap between the turns.

[0073] Second Embodiment The reactor 1 of the second embodiment will be described with reference to Fig. 7 to Fig. 10. The reactor 1 of the second embodiment differs from the reactor 1 of the first embodiment in that the number of the coil 2 is one, and that the planar shape of the magnetic core 3 as viewed from the Z1 direction is θ-shaped. The following description will focus on the differences from the first embodiment. Description of the same configuration and effects as the first embodiment will be omitted.

[0074] [coil] The coil 2 has a winding 20 wound around the outer circumferential surface of the inner core portion 31. The number of coils 2 is one. The reactor 1 of this example has a smaller number of parts than when the reactor 1 has a plurality of coils 2. Therefore, the reactor 1 of this example has excellent productivity.

[0075] The first end 201 of the winding 20 is drawn out in the Y2 direction from the turn constituting the first end surface of the coil 2 along the Y2 direction. The second end 202 of the winding 20 is drawn out in the Y2 direction from the turn constituting the second end surface of the coil 2 along the Y2 direction. Specifically, the first end 201 of the winding 20 is drawn out such that a surface facing the Z2 direction is substantially flush with the second coil surface 212. The second end 202 of the winding 20 is drawn out such that a surface facing the Z1 direction is substantially flush with the first coil surface 211.

[0076] The second end 202 of the winding 20 is disposed in a groove 335, which will be described later. The second end 202 of the winding 20 is in direct contact with the inner surface of the groove 335, except for the surface of the second end 202 of the winding 20 facing the Z1 direction. The second end 202 of the winding 20 has a surface that is substantially flush with the first coil surface 211 and an area that is in direct contact with the inner surface of the groove 335. The first end 201 of the winding 20 is disposed in a groove, not shown. The configuration of the groove in which the first end 201 is disposed is the same as that of the groove 335. The first end 201 of the winding 20 is in direct contact with the inner surface of the groove, except for the surface of the first end 201 of the winding 20 facing the Z2 direction. That is, the first end 201 of the winding 20 has a surface that is substantially flush with the second coil surface 212 and an area that is in direct contact with the inner surface of the groove.

[0077] [Magnetic core] (Outer core part) The outer core portion 32 of this example has a first end core portion 34f, a second end core portion 34s, a first side core portion 33f, and a second side core portion 33s. The first side core portion 33f and the second side core portion 33s are arranged on the outer periphery of the coil 2 so as to sandwich the inner core portion 31 shown in FIG. 9. That is, as shown in FIG. 9, the first side core portion 33f, the inner core portion 31, and the second side core portion 33s are arranged in parallel in this order along the Y2 direction. First ends of the first side core portion 33f and the second side core portion 33s are connected to the first end core portion 34f, and second ends of the first side core portion 33f and the second side core portion 33s are connected to the second end core portion 34s. The surface of the first side core portion 33f facing the Y2 direction is in direct contact with the surface of a first protruding portion 42f of a first spacer 41f described later facing the Y1 direction. The surface of the second side core portion 33s facing the Y1 direction is in direct contact with the surface of the second protruding portion 42s of the first spacer 41f facing the Y2 direction. The first side core portion 33f and the second side core portion 33s have the same configuration. The following description will mainly focus on the second side core portion 33s.

[0078] The second side core portion 33s has a quadrangular prism shape. The outer peripheral shape of the second side core portion 33s as viewed from the X1 direction is rectangular. The four corners of the second side core portion 33s are angular, but may be rounded. In this example, the length of the second side core portion 33s along the Y1 direction is shorter than the length of the second side core portion 33s along the Z1 direction. Unlike this example, the length of the second side core portion 33s along the Y1 direction may be the same as the length of the second side core portion 33s along the Z1 direction, or the length of the second side core portion 33s along the Y1 direction may be longer than the length of the second side core portion 33s along the Z1 direction.

[0079] The outer peripheral surface of the second side core portion 33s has a first core surface 331 and a second core surface 332 facing each other. The first core surface 331 and the second core surface 332 are along the short side of the rectangular outer peripheral shape. The first core surface 331 is substantially flush with the first coil surface 211 and both first core surfaces 341. The second core surface 332 is substantially flush with the second coil surface 212 and both second core surfaces 342. Therefore, the maximum difference in the Z1 direction between the first coil surface 211 and both first core surfaces 341 and the first core surface 331 and the maximum difference in the Z2 direction between the second coil surface 212 and both second core surfaces 342 and the second core surface 332 can be reduced, and both maximum differences can be brought close to 0 (zero). The reactor 1 has excellent heat dissipation properties because both first core surfaces 331 or both second core surfaces 332 are also brought into contact with the installation target.

[0080] Unlike this example, first core surface 331 does not have to be flush with first coil surface 211 , and second core surface 332 does not have to be flush with second coil surface 212 .

[0081] The second side core portion 33s has a groove 335 provided in the first core surface 331 as shown in FIG. 9. The second side core portion 33s has a groove provided in the second core surface 332, although not shown. The groove 335 in the first core surface 331 and the groove (not shown) in the second core surface 332 are grooves formed according to the second end 202 and the first end 201 of the winding 20 when the second side core portion 33s is formed. The second end 202 of the winding 20 is arranged in the groove 335 in the first core surface 331. The first end 201 of the winding 20 is arranged in the groove (not shown) in the second core surface 332. The width of the groove 335 in the first core surface 331 and the groove (not shown) in the second core surface 332 is the same as the thickness of the winding 20, which is a coated rectangular wire. The depth of the grooves 335 of the first core surface 331 and the grooves (not shown) of the second core surface 332 is the same as the width of the winding 20, which is a coated rectangular wire. The first side core portion 33f of this example does not have the grooves 335 described in the second side core portion 33s.

[0082] The inner core portion 31, the first end core portion 34f, the second end core portion 34s, the first side core portion 33f and the second side core portion 33s are an integral molding of a composite material.

[0083] [Spacer] The planar shape of the first spacer 41f and the second spacer 41s of this example as viewed from the Z1 direction is U-shaped as shown in Fig. 10. The first spacer 41f and the second spacer 41s of this example further include a first protrusion 42f and a second protrusion 42s in addition to the base portion 42a and the guide portion 43. The first spacer 41f and the second spacer 41s have the same configuration. The following description will mainly focus on the second spacer 41s.

[0084] The first protrusion 42f and the second protrusion 42s of the second spacer 41s extend in the X1 direction from the Y1-direction end and the Y2-direction end of the base 42a. The first protrusion 42f is disposed between the coil 2 and the first side core portion 33f. The second protrusion 42s is disposed between the coil 2 and the second side core portion 33s. The first protrusion 42f and the second protrusion 42s are C-shaped. The C-shaped first protrusion 42f and the C-shaped second protrusion 42s are provided at both ends of the base 42a with their openings facing each other.

[0085] The first protrusion 42f and the second protrusion 42s have a first surface 423 and a second surface 424 facing each other. The first surface 423 and the second surface 424 are flat surfaces. The first surface 423 is substantially flush with the first surface 421. The second surface 424 is substantially flush with the second surface 422.

[0086] The second protrusion 42s of the second spacer 41s has a groove 46. The groove 46 leads out the second end 202. The groove 46 is provided on the surface of the second protrusion 42s facing the Z1 direction. The groove 46 is provided at the end of the second protrusion 42s in the X2 direction. The width of the groove 46 is greater than the thickness of the winding 20, which is a coated rectangular wire. The depth of the groove 46 is the same as the width of the winding 20, which is a coated rectangular wire. The second protrusion 42s of the first spacer 41f has a groove (not shown). The groove leads out the first end 201. The groove (not shown) is provided on the surface of the second protrusion 42s facing the Z2 direction. The groove (not shown) is provided at the end of the second protrusion 42s in the X1 direction. The width and depth of the groove (not shown) are the same as the width and depth of the groove 46.

[0087] Third Embodiment As shown in FIG. 11, in the reactor 1 of the third embodiment, the coil 2 may have an insulating layer 25 provided along the inner peripheral surface of the coil 2. The insulating layer 25 tends to increase the electrical insulation between the coil 2 and the inner core portion 31. The insulating layer 25 is made of, for example, the resin constituting the above-mentioned composite material molded body or the same resin as the resin constituting the spacer 4. The insulating layer 25 is disposed in the groove portion 31a of the inner core portion 31. The thickness of the insulating layer 25 is, for example, 500 μm or less, further 300 μm or less, particularly 100 μm or less. The insulating layer 25 is formed on the inner peripheral surface of the coil 2 before placing the coil 2 in the mold. The insulating layer 25 can be formed, for example, by applying an insulating material or attaching an insulating sheet.

[0088] Fourth Embodiment 12, in the reactor 1 of the fourth embodiment, the first winding 20f may be a round wire, and the contour shape of each groove 31a may be U-shaped. The width and depth of each groove 31a are the same as the diameter of the winding 20.

[0089] Fifth Embodiment [Converter / Power Conversion Device] The reactor 1 according to any one of the first to fourth embodiments can be used for applications that satisfy the following current-carrying conditions. The maximum DC current is, for example, about 100 A or more and 1000 A or less. The average voltage is, for example, about 100 V or more and 1000 V or less. The frequency used is, for example, about 5 kHz or more and 100 kHz or less. The reactor 1 according to any one of the first to fourth embodiments can be used as a component of a converter mounted on a vehicle 1200, typically an electric vehicle, a hybrid vehicle, or a fuel cell vehicle, or as a component of a power conversion device including this converter.

[0090] As shown in Fig. 13, the vehicle 1200 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. The motor 1220 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. Although Fig. 13 shows an inlet as a charging point for the vehicle 1200, a form including a plug may be used.

[0091] The power conversion device 1100 includes a converter 1110 and an inverter 1120. The converter 1110 is connected to a main battery 1210. The inverter 1120 is connected to the converter 1110. The inverter 1120 converts between DC and AC. 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 during the running of the vehicle 1200, and supplies the power to the inverter 1120. During regeneration, the converter 1110 reduces the input voltage output from the motor 1220 via the inverter 1120 to a DC voltage suitable for the main battery 1210, and charges the main battery 1210. The input voltage is a DC voltage. During the running of the vehicle 1200, the inverter 1120 converts the DC boosted by the converter 1110 into a predetermined AC voltage and supplies the power 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 .

[0092] As shown in FIG. 14, 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. The converter 1110 converts the input voltage by repeatedly turning the switching elements on and off. The conversion of the input voltage means stepping up and down the voltage here. The switching elements 1111 include 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 the change when the current increases or decreases due to the switching operation. The reactor 1115 includes the reactor 1 of any one of the first to fourth embodiments. The power conversion device 1100 and the converter 1110 that include the reactor 1 are expected to have improved heat dissipation.

[0093] In addition to the converter 1110, the vehicle 1200 includes a converter 1150 for a power supply device and a converter 1160 for an auxiliary power supply. The converter 1150 for a power supply device is connected to a main battery 1210. The converter 1160 for an auxiliary power supply is connected to a sub-battery 1230 that serves as a power source for the auxiliary devices 1240 and the main battery 1210. The converter 1160 for an auxiliary power supply converts a high voltage of the main battery 1210 to a low voltage. The converter 1110 typically performs DC-DC conversion, and 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 be reactors having the same configuration as the reactor 1 of any one of the first to fourth embodiments, but with the size, shape, and the like appropriately changed. Furthermore, the reactor 1 according to any one of the first to fourth embodiments can be used in a converter that converts input power and that only performs step-up or step-down.

[0094] The present invention is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims.

[0095] For example, the number of coils may be one, and the planar shape of the magnetic core may be a rectangular ring. The magnetic core has an inner core portion, a side core portion, a first end core portion, and a second end core portion. The coil has a winding wound along the outer circumferential surface of the inner core portion. The side core portion is arranged in parallel with the inner core portion. The side core portion is arranged on the outer periphery of the coil. In other words, no coil is wound around the outer circumferential surface of the side core portion. The first end core portion is connected to first ends of the inner core portion and the side core portion. The second end core portion is connected to second ends of the inner core portion and the side core portion.

[0096] Alternatively, for example, the magnetic core may have a circular planar shape. [Explanation of symbols]

[0097] 1 Reactor 2 Coil 20 Windings 20f First Winding 20s Second Winding 201 First end 202 Second end 21f First winding part 21s Second winding part 211 First coil surface 212 Second coil surface 25 Insulating layer 3. Magnetic core 31 Inner core part 31f First inner core part 31s Second inner core part 31a Groove 31b Recess 32 Outer core 33f First side core part 33s Second side core part 331 First Core Surface 332 Second Core Surface 335 Groove 34f First end core section 34s second end core part 341 First Core Surface 342 Second Core Surface 35 Gate Remains 4 Spacer 41f First spacer 41s Second spacer 42a base 421 Front page 422 Second side 42f First protrusion 42s second protrusion 423 Front page 424 Second side 43 Guide section 44 Through hole 451 All missing 452 Second notch 46 Groove 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 and a magnetic core having an inner core portion disposed inside the coil and an outer core portion disposed outside the coil, The coil has a winding wound along an outer circumferential surface of the inner core portion, The outer circumferential shape of the coil is rectangular when viewed from a first direction along the axis of the coil, the outer circumferential surface of the coil has a first coil surface and a second coil surface that are along each of the long sides of the outer circumferential shape of the coil and face each other, the first coil surface and the second coil surface are exposed from the outer core portion, At least an outer circumferential region of the inner core portion is formed of a composite material molding, an outer circumferential surface of the inner core portion has a plurality of grooves aligned in a direction along the axis of the inner core portion; the winding of each turn of the coil is disposed in each of the plurality of grooves; Reactor.

2. the inner core portion and the outer core portion are an integral molded body, The reactor according to claim 1 , wherein the inner core portion and the outer core portion are entirely made of a molded body of the composite material.

3. the outer core portion has a first end core portion facing a first end surface of the coil and a second end core portion facing a second end surface of the coil, The reactor according to claim 2 , wherein at least one of the first end core portion and the second end core portion has a gate mark.

4. the coil has a first winding portion and a second winding portion arranged in parallel with each other, The reactor according to claim 3 , wherein the inner core portion has a first inner core portion arranged inside the first winding portion and a second inner core portion arranged inside the second winding portion.

5. The number of the coils is one, The reactor according to claim 3 , wherein the outer core portion further comprises at least one side core portion arranged in parallel with the inner core portion.

6. A reactor according to any one of claims 1 to 3, converter.

7. A converter comprising: Power conversion equipment.

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