Reactor, converter, and power conversion device

Abstract

To provide a reactor that has excellent rigidity in a holding member for positioning a coil and has excellent productivity.SOLUTION: A reactor comprises: a coil which has a winding part composed of a plurality of turns of winding; a first holding member which is disposed so as to face a first end surface of the winding part; and a second holding member which is disposed so as to face a second end surface of the winding part. Each of the plurality of turns comprises a first linear part, a first curved part, a second linear part and a second curved part arranged sequentially around the axis of the winding part. Each of the first and second holding members includes two protrusions for positioning the winding part. The two protrusions include: a first protrusion that contacts at least a portion of the first curved part; and a second protrusion that contacts at least a portion of the second curved part.SELECTED DRAWING: Figure 4

Description

Technical Field

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

Background Art

[0002] Patent Document 1 discloses a reactor including a coil, a magnetic core, and a holding member. The coil includes a main body portion composed of a plurality of turns. Each turn has four straight portions where the winding is linearly arranged and four corner portions where the winding is bent. The holding member is disposed at each end of the main body portion and ensures electrical insulation between the main body portion and the magnetic core. The holding member has a plurality of inner protrusions for positioning the coil. The plurality of inner protrusions are typically provided at locations corresponding to each side of the inner peripheral surface of the main body portion.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] A holding member having high rigidity is required. In the holding member disclosed in Patent Document 1, one or more inner protrusions are provided at each location corresponding to the four straight portions of the turns constituting the main body portion. The number of inner protrusions is large, and the size of each inner protrusion is small. The small inner protrusions have low rigidity, and the positioning accuracy of the coil is likely to deteriorate. When the number of inner protrusions is large, the moldability of the inner protrusions, for example, the number of objects to be inspected for the presence or absence of nests and dimensions increases, and productivity decreases.

[0005] One object of the present disclosure is to provide a reactor that is excellent in the rigidity of a holding member for positioning a coil and excellent in productivity. Another object of the present disclosure is to provide a converter including the reactor. Another object of the present disclosure is to provide a power conversion device including the converter.

Means for Solving the Problems

[0006] The reactor of the present disclosure includes a coil having a winding portion composed of a plurality of turns of wire, a first holding member disposed so as to face a first end surface of the winding portion, and a second holding member disposed so as to face a second end surface of the winding portion. Each of the plurality of turns is composed of a first straight portion, a first curved portion, a second straight portion, and a second curved portion that are sequentially arranged around the axis of the winding portion. Each of the first holding member and the second holding member includes two protrusions for positioning the winding portion. The two protrusions are composed of a first protrusion that contacts at least a part of the first curved portion and a second protrusion that contacts at least a part of the second curved portion.

Effects of the Invention

[0007] The reactor of the present disclosure is excellent in the rigidity of a holding member for positioning a coil.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

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Figure 6

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Figure 8

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Figure 11

Figure 12

Figure 13

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Figure 15

MODE FOR CARRYING OUT THE INVENTION

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

[0010] (1) The reactor according to an embodiment of the present disclosure includes a coil having a winding portion composed of a plurality of turns of wire, a first holding member disposed to face the first end surface of the winding portion, and a second holding member disposed to face the second end surface of the winding portion. Each of the plurality of turns is composed of a first straight portion, a first curved portion, a second straight portion, and a second curved portion arranged in order around the axis of the winding portion. Each of the first holding member and the second holding member includes two protruding portions for positioning the winding portion. The two protruding portions are composed of a first protruding portion that contacts at least a part of the first curved portion and a second protruding portion that contacts at least a part of the second curved portion.

[0011] Since the number of protruding portions of the first holding member or the second holding member provided at one end of one winding portion is two, the number of objects to be inspected for the moldability of the protruding portions is small. The inspection of the moldability of the protruding portions is, for example, the presence or absence of voids and dimensional control. A reactor with a small number of objects to be inspected is excellent in productivity. Even if the number of protruding portions of each of the first holding member and the second holding member is two for each end of one winding portion, since the two protruding portions are provided corresponding to the first curved portion and the second curved portion among the turns constituting the winding portion, it is easy to increase the size of each protruding portion. The curved portion is a portion composed only of a curve and does not include a portion composed of a straight line. A large protruding portion has high rigidity. A holding member having a large protruding portion is excellent in rigidity.

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

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

[0014] (3) In the reactor according to the above (1) or (2), each of the first protrusion and the second protrusion may have a shape along the inner peripheral shape of the winding portion.

[0015] When the shape of each of the first protrusion and the second protrusion follows the inner peripheral shape of the winding portion, that is, follows the shape of each of the first curved portion and the second curved portion, it is easy to support the first curved portion with the first protrusion and to support the second curved portion with the second protrusion. Even with two protrusions, if both curved portions can be supported, the positioning of the winding portion can be performed with high accuracy.

[0016] (4) In the reactor according to any one of the above (1) to (3), the coil may be an edgewise coil formed of a rectangular wire.

[0017] An edgewise coil formed of a rectangular wire can shorten the length of the winding portion. The length of the winding portion is the length along the axis of the winding portion.

[0018] (5) In the reactor according to any one of the above (1) to (4), the first length of each of the first straight portion and the second straight portion may be longer than the second length between the first straight portion and the second straight portion.

[0019] A winding portion in which the first length is longer than the second length is flat. If the winding portion is flat, the entire reactor is likely to be flat. A flat reactor is easy to arrange in any space and has excellent freedom of arrangement.

[0020] (6) The converter according to an embodiment of the present disclosure includes the reactor according to any one of the above (1) to (5).

[0021] The converter including the above reactor is excellent in productivity.

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

[0023] The power conversion device including the above converter is excellent in productivity.

[0024] [Details of Embodiments of the Present Disclosure] Specific examples of embodiments of the present disclosure will be described below with reference to the drawings. The same reference numerals in the figures denote the same objects. In each drawing, for convenience of explanation, a part of the configuration may be exaggerated or simplified. The dimensional ratios of the respective parts in the drawings may also differ from the actual ones. Note that the present invention is not limited to these examples, but is shown by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0025] <Embodiment 1> With reference to FIGS. 1 to 6, the reactor 1α of Embodiment 1 will be described. As shown in FIG. 1, the reactor 1α includes a coil 2, a first holding member 5, a second holding member 6, and a magnetic core 8. The coil 2 has a winding portion 20 formed of a winding 3 having a plurality of turns 4. One of the features of the reactor 1α is that, as shown in FIG. 4, each turn 4 is composed of a first straight portion 41, a first curved portion 43, a second straight portion 42, and a second curved portion 44. Another feature of the reactor 1α is that, as shown in FIGS. 3 and 4, the first holding member 5 includes two protrusions formed of a first protrusion 51 and a second protrusion 52. Still another feature of the reactor 1α is that, as shown in FIGS. 2 and 3, the second holding member 6 includes two protrusions formed of a first protrusion 61 and a second protrusion 62. The first protrusion 51 and the second protrusion 52 of the first holding member 5, and the first protrusion 61 and the second protrusion 62 of the second holding member 6 are provided corresponding to the number of the winding portions 20.

[0026] ≪Coil≫ Coil 2 has at least one winding portion 20. The coil 2 in this example has one winding portion 20. The winding portion 20 is formed by winding a winding wire 3 in a spiral shape. Both ends of the winding wire 3 are drawn out from each end of the winding portion 20. Terminal fittings (not shown) are attached to both ends of the winding wire 3 drawn out from the winding portion 20. An external device (not shown) is connected to the terminal fittings. In each drawing, only the winding portion 20 is shown, and both ends of the winding wire 3 are omitted.

[0027] As the winding wire 3, a known winding wire can be used. The winding wire 3 in this example is a rectangular wire having a conductor wire and an insulating coating covering the conductor wire. The conductor wire is made of, for example, a rectangular wire made of copper. The insulating coating is made of, for example, enamel. The coil 2 in this example is an edgewise coil composed of rectangular wires. The edgewise coil composed of rectangular wires can shorten the length along the axis of the winding portion 20. The length of the winding portion 20 is the length along the axis of the winding portion 20.

[0028] The winding portion 20 is composed of a plurality of turns 4. As shown in FIG. 4, each turn 4 is composed of a first straight portion 41, a first curved portion 43, a second straight portion 42, and a second curved portion 44 arranged in order around the axis of the winding portion 20. FIG. 4 shows any one of the plurality of turns 4. In FIG. 4, the transition locations between adjacent turns 4 are virtually shown by a two-dot chain line. For convenience of explanation, FIG. 4 shows a state in which a first holding member 5 described later is assembled to the winding portion 20.

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

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

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

[0032] The winding portion 20 with the length L1 longer than the length L2 has a flat shape that is thinner in the third direction D3. The turn 4 composed of the first straight portion 41, the first curved portion 43, the second straight portion 42, and the second curved portion 44 is suitable for the flat winding portion 20. In the flat winding portion 20, the ratio L2 / L1 of the length L2 to the length L1 is, for example, 1 / 10 or more and 1 / 3 or less. The ratio L2 / L1 may be 1 / 10 or more and 1 / 4 or less, or 1 / 10 or more and 1 / 5 or less. If the winding portion 20 is flat, the entire reactor 1α is also likely to be flat. The flat reactor 1α is easy to be arranged in any space and has excellent freedom of arrangement.

[0033] Each of the first curved portion 43 and the second curved portion 44 has, for example, a semi-circular shape. If each of the shapes of the first curved portion 43 and the second curved portion 44 is a semi-circular shape, it is easy to manufacture the flat winding portion 20. The first curved portion 43 and the second curved portion 44 may be composed of any curve as long as they do not include a portion composed of a straight line. The shapes of the first curved portion 43 and the second curved portion 44 may be semi-elliptical shapes. The first curved portion 43 and the second curved portion 44 are formed by the winding wire 3 bending along the outer peripheral surface of a shaft (not shown) in the manufacturing process of the coil 2. By changing the shape of this shaft, the shapes of the first curved portion 43 and the second curved portion 44 can be made into semi-circular shapes or semi-elliptical shapes.

[0034] ≪First Holding Member≫ As shown in FIG. 3, the first holding member 5 is arranged to face the first end face 21 of the winding portion 20. The first holding member 5 has a function of ensuring electrical insulation between the winding portion 20 and the first end core portion 821 described later. The first holding member 5 includes a main body portion 50, a first protrusion portion 51, and a second protrusion portion 52. The first holding member 5 of this example further includes a side portion 55.

[0035] The main body portion 50 is a plate-like member disposed between the winding portion 20 and the first end core portion 821. The main body portion 50 includes a through hole 50h that penetrates the front and back of the main body portion 50. The through hole 50h is provided to connect the inner core portion 81 and the first end core portion 821, which will be described later. The shape of the through hole 50h is substantially similar to the contour shape of each turn 4. The contour shape of the through hole 50h is a racetrack shape. The contour shape of the through hole 50h has a flat shape that is thinner in the third direction D3.

[0036] The first protrusion 51 and the second protrusion 52 have a function of positioning the winding portion 20. The first holding member 5 is provided with two protrusions for positioning the winding portion 20. These two protrusions are the first protrusion 51 and the second protrusion 52. In other words, the first holding member 5 is not provided with protrusions for positioning the winding portion 20 other than the first protrusion 51 and the second protrusion 52.

[0037] The first protrusion 51 and the second protrusion 52 are provided at positions on the inner peripheral surface of the through hole 50h that face each other. At the positions on the inner peripheral surface of the through hole 50h where the first protrusion 51 and the second protrusion 52 are provided, they protrude by the thickness of each of the first protrusion 51 and the second protrusion 52 compared to other positions. The first protrusion 51 and the second protrusion 52 protrude toward the second holding member 6 along the first direction D1 from the surface of the main body portion 50 that faces the first end surface 21 of the winding portion 20. The protruding length of the first protrusion 51 and the second protrusion 52 has a length that contacts, for example, two or more turns of the winding portion 20. This protruding length is the length along the first direction D1 of the first protrusion 51 and the second protrusion 52 from the surface of the main body portion 50 that faces the first end surface 21. When the first protrusion 51 and the second protrusion 52 are provided so as to contact two or more turns from each end of the winding portion 20, it is easy to accurately position the coil 2 by the first holding member 5. The protruding length of the first protrusion 51 and the second protrusion 52 in this example has a length that contacts two turns of the winding portion 20.

[0038] The first protrusion 51 is provided so as to be in contact with at least a part of the first curved portion 43 shown in FIG. 4. The first protrusion 51 of this example is provided so as to be in contact with the inner surface of the first curved portion 43. The first protrusion 51 of this example has a shape along the inner peripheral shape of the winding portion 20. In this example, the outer peripheral surface of the first protrusion 51 and the inner peripheral surface of the winding portion 20 are flush. The first protrusion 51 of this example has a shape along the inner surface shape of the first curved portion 43. In this example, the first curved portion 43 has a semi-circular shape, and the first protrusion 51 also has a semi-circular shape. Even if there is a portion provided with a slight clearance between the first protrusion 51 and the first curved portion 43 as long as the first protrusion 51 has a shape along the inner surface shape of the first curved portion 43. The first protrusion 51 may be provided so as to be in contact with not only the first curved portion 43 but also a part of the first straight portion 41 and a part of the second straight portion 42. By providing the first protrusion 51 so as to be in contact with only the first curved portion 43, it is easy to assemble the first protrusion 51 to the winding portion 20. When the first protrusion 51 is provided so as to be in contact with the entire surface of the first curved portion 43 as viewed from the first direction D1, the strength of the first protrusion 51 is higher than that in contact with a part of the first curved portion 43, and it is easier to stably support the winding portion 20. The first protrusion 51 may be provided so as to be in contact with a part of the first curved portion 43. In this case, the first protrusion 51 is in contact with, for example, the outermost position in the second direction D2 in the first curved portion 43.

[0039] The second protruding portion 52 is provided so as to be in contact with at least a part of the second curved portion 44 shown in FIG. 4. The second protruding portion 52 of this example is provided so as to be in contact with the inner surface of the second curved portion 44. The second protruding portion 52 of this example has a shape along the inner peripheral shape of the winding portion 20. In this example, the outer peripheral surface of the second protruding portion 52 and the inner peripheral surface of the winding portion 20 are flush. The second protruding portion 52 of this example has a shape along the inner surface shape of the second curved portion 44. In this example, the second curved portion 44 has a semi-circular shape, and the second protruding portion 52 also has a semi-circular shape. Even if the second protruding portion 52 has a shape along the inner surface shape of the second curved portion 44, there may be a portion where a slight clearance is provided between the second protruding portion 52 and the second curved portion 44. In addition to the second curved portion 44, the second protruding portion 52 may be provided so as to be in contact with a part of the first straight portion 41 and a part of the second straight portion 42. By providing the second protruding portion 52 so as to be in contact only with the second curved portion 44, it is easy to assemble the second protruding portion 52 to the winding portion 20. When the second protruding portion 52 is provided so as to be in contact with the entire surface of the second curved portion 44 when viewed from the first direction D1, the strength of the second protruding portion 52 is higher than that when it is in contact with a part of the second curved portion 44, and it is easy to stably support the winding portion 20. The second protruding portion 52 may be provided so as to be in contact with a part of the second curved portion 44. In this case, the second protruding portion 52 is in contact with, for example, the outermost position in the second direction D2 in the second curved portion 44.

[0040] The first protrusion 51 and the second protrusion 52 are, for example, symmetrical. Symmetrical means that if the first protrusion 51 is rotated 180° around the axis of the winding portion 20, it will coincide with the second protrusion 52. The first protrusion 51 and the second protrusion 52 may be asymmetrical. The first protrusion 51 and the second protrusion 52 may have different protruding lengths along the first direction D1. The first protrusion 51 and the second protrusion 52 may have different lengths around the axis of the winding portion 20. The first protrusion 51 and the second protrusion 52 are provided so as to be in contact with the outermost positions of each other in the first curved portion 43 and the second curved portion 44. The first protrusion 51 and the second protrusion only need to have a region facing each other and overlapping, and not all regions need to overlap. The region where the first protrusion 51 and the second protrusion 52 face each other and overlap is the region in contact with the outermost positions of each other in the first curved portion 43 and the second curved portion 44.

[0041] The first protrusion 51 may be provided so as to be in contact with at least a part of the outer surface of the first curved portion 43, and the second protrusion 52 may be provided so as to be in contact with at least a part of the outer surface of the second curved portion 44. In this case, each of the first protrusion 51 and the second protrusion 52 may have a shape along the outer peripheral shape of the winding portion 20.

[0042] Since there are two protrusions provided on the first holding member 5, namely the first protrusion 51 and the second protrusion 52, the number of objects to be inspected for the moldability of the protrusions is small. Even if the number of protrusions provided on the first holding member 5 is two, since the first protrusion 51 corresponds to the first curved portion 43 and the second protrusion 52 corresponds to the second curved portion 44, it is easy to increase the rigidity of the first protrusion 51 and the second protrusion 52. The first holding member 5 having the first protrusion 51 and the second protrusion 52 with high rigidity is excellent in rigidity.

[0043] As shown in FIGS. 2 and 3, the side portion 55 is provided so as to extend in the first direction D1 from one end portion of the main body portion 50 in the second direction D2. The side portion 55 is disposed between the side core portion 823 shown in FIG. 1 and the winding portion 20. The surface of the side portion 55 facing the winding portion 20 is an arc surface along the outer shape of the winding portion 20 as shown in FIG. 3. An engaging portion (not shown) may be provided at the tip end portion of the side portion 55 in the first direction D1. This engaging portion engages with an engaging portion (not shown) provided on the side portion 65 of the second holding member 6 described later. A gap 7 is provided between the side portion 55 and the winding portion 20, for example, as shown in FIG. 4. When the gap 7 is provided, it is easy to dispose each of the first protrusion 51 and the second protrusion 52 on the inner peripheral surface of the winding portion 20. When the gap 7 is provided, it is not necessary to accurately correspond the distance between the first protrusion 51 and the side portion 55 to the width of the winding wire 3, and high molding accuracy is not required.

[0044] The side portion 55 has a function of determining the relative positions of the first holding member 5 and the second holding member 6. Further, when the side core portion 823 described later is made of a composite material, the side portion 55 also has a function of suppressing the composite material from contacting the winding portion 20 during the molding of the side core portion 823.

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

[0046] <<Second Holding Member>> As shown in FIG. 3, the second holding member 6 is disposed to face the second end face 22 of the winding portion 20. The second holding member 6 has a function of ensuring electrical insulation between the winding portion 20 and a second end core portion 822 described later. The second holding member 6 includes a main body portion 60, a first protrusion portion 61, and a second protrusion portion 62. The main body portion 60 is a plate-like member disposed between the winding portion 20 and the second end core portion 822. The main body portion 60 includes a through hole 60h that penetrates the front and back of the main body portion 60. The second holding member 6 of this example further includes a side portion 65.

[0047] The second holding member 6 has the same configuration as the first holding member 5. By respectively replacing the "main body portion 50", "through hole 50h", "first protrusion portion 51", "second protrusion portion 52", and "side portion 55" of the first holding member 5 described above with the "main body portion 60", "through hole 60h", "first protrusion portion 61", "second protrusion portion 62", and "side portion 65", the description of the second holding member 6 is obtained.

[0048] Since there are two protrusion portions provided on the second holding member 6, namely the first protrusion portion 61 and the second protrusion portion 62, the number of objects to be inspected for the moldability of the protrusion portions is small. Even though the number of protrusion portions provided on the second holding member 6 is two, the first protrusion portion 61 corresponds to the first curved portion 43 and the second protrusion portion 62 corresponds to the second curved portion 44, making it easy to increase the rigidity of the first protrusion portion 61 and the second protrusion portion 62. The second holding member 6 having the first protrusion portion 61 and the second protrusion portion 62 with high rigidity is excellent in rigidity.

[0049] The second holding member 6 of this example has the same shape and the same dimensions as the first holding member 5. The second holding member 6 of this example coincides with the first holding member 5 when rotated 180° around an axis parallel to the second direction D2. The first holding member 5 and the second holding member 6 may have portions with different shapes from each other or portions with different dimensions from each other.

[0050] ≪Magnetic Core≫ The coil 2 is disposed on the magnetic core 8. As shown in FIG. 5, the magnetic core 8 includes an inner core portion 81 and an outer core portion 82. By configuring the inner core portion 81 and the outer core portion 82 in series, a closed magnetic path through which magnetic flux flows when the coil 2 is excited is formed in the magnetic core 8. The magnetic core 8 in this example is an integral molded product in which the inner core portion 81 and the outer core portion 82 are configured without joints. The magnetic core 8 in this example is composed of a molded body of a composite material described later.

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

[0052] The shape of the inner core portion 81 is a shape generally corresponding to the inner peripheral shape of the winding portion 20. As shown in FIGS. 5 and 6, two recesses 810 are provided at both end portions of the inner core portion 81 in this example. In FIG. 6, for convenience of explanation, a state in which the first holding member 5 is assembled to the first end portion of the inner core portion 81 is shown. In FIG. 6, the outer core portion 82 shown in FIG. 5 is not shown for easy understanding.

[0053] The two recesses 810 provided at the first end portion of the inner core portion 81 are provided corresponding to the first protrusion 51 and the second protrusion 52 provided on the first holding member 5. A part of the first end portion of the inner core portion 81 is fitted into a through hole 50h provided in the main body portion 50 of the first holding member 5. In a state where the first holding member 5 is assembled to the first end portion of the inner core portion 81, the outer peripheral surface of the inner core portion 81, the outer surface of the first protrusion 51, and the outer surface of the second protrusion 52 are flush.

[0054] The two recesses 810 provided at the second end portion of the inner core portion 81 are provided corresponding to the first protrusion portion 61 and the second protrusion portion 62 provided on the second holding member 6 shown in FIGS. 2 and 3. A part of the second end portion of the inner core portion 81 is fitted into a through hole 60h provided in the main body portion 60 of the second holding member 6. In a state where the second holding member 6 is assembled to the second end portion of the inner core portion 81, the outer peripheral surface of the inner core portion 81, the outer surface of the first protrusion portion 61, and the outer surface of the second protrusion portion 62 are flush.

[0055] The outer core portion 82 is a portion disposed outside the winding portion 20 of the coil 2. The shape of the outer core portion 82 is not particularly limited as long as it is a shape connected to the end portion of the inner core portion 81. As shown in FIGS. 1 and 5, the outer core portion 82 of this example includes a first end core portion 821, a second end core portion 822, and a side core portion 823. The first end core portion 821 is provided so as to face the first holding member 5 and is connected to the first end portion of the inner core portion 81. The second end core portion 822 is provided so as to face the second holding member 6 and is connected to the second end portion of the inner core portion 81. The side core portion 823 connects the first end core portion 821 and the second end core portion 822. The shape of the outer core portion 82 to which the first end core portion 821, the second end core portion 822, and the side core portion 823 are connected is a rectangular C shape when viewed from the third direction D3.

[0056] The magnetic core 8 in this example is composed of a molded body of a composite material. The molded body of the composite material is manufactured by filling a mold with a raw material in which soft magnetic powder is mixed and dispersed in an uncured resin and then curing the resin. The magnetic core 8 is manufactured, for example, as follows. A combination in which the first holding member 5 and the second holding member 6 are assembled to the coil 2 as shown in FIG. 2 is produced. This combination is placed in a mold. The mold in which the combination is placed is filled with the above raw material. The filling of the raw material is performed from a location corresponding to either the first end core portion 821 or the second end core portion 822. The above raw material flows along the shape of the mold and the inner peripheral shape of the winding portion 20. When the resin is cured, a magnetic core 8 as shown in FIG. 5 is formed, and a reactor 1α as shown in FIG. 1 is manufactured. In the inner core portion 81, the concave portion 810 is in direct contact with the first protrusions 51, 61 and the second protrusions 52, 62, and the portions other than the concave portion 810 are in direct contact with the inner peripheral surface of the winding portion 20.

[0057] The composite material can easily control magnetic properties, such as permeability or saturation magnetic flux density, by adjusting the content ratio of the soft magnetic powder in the resin. In particular, the composite material can easily adjust the content ratio of the soft magnetic powder to be small and can easily lower the permeability. The molded body of the composite material is easier to mold into a complex shape compared to the compacted molded body described later. If it is a molded body of the composite material, it is easy to mold a magnetic core 8 corresponding to a relatively complex shape such as the first protrusions 51 and the second protrusions 52.

[0058] The soft magnetic powder is composed of, for example, particles of a soft magnetic metal, coated particles, or particles of a soft magnetic non-metal. The coated particles include particles of a soft magnetic metal and an insulating coating provided on the outer periphery of the particles of the soft magnetic metal. 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 non-metal is, for example, a ferrite. The content ratio of the soft magnetic powder in the molded body of the composite material is, for example, 20% by volume or more and 80% by volume or less when the composite material is 100% by volume. The resin is, for example, a PPS resin, a PTFE resin, an LCP, a PA resin, a PBT resin, or an ABS resin. The resin may also be a BMC (Bulk molding compound) in which calcium carbonate or glass fiber is mixed with an unsaturated polyester, a millable silicone rubber, or a millable urethane rubber.

[0059] The magnetic core 8 may be composed of a compacted powder molded body. The magnetic core 8 composed of a compacted powder molded body has a plurality of core pieces. The magnetic core 8 composed of a compacted powder molded body has joints between the core pieces at any location of the magnetic core 8. The magnetic core 8 may be configured by combining a core piece made of a compacted powder molded body and a core piece made of a molded body of a composite material. The magnetic core 8 may be configured such that the outer periphery of a core piece made of a compacted powder molded body is covered with a composite material.

[0060] The compacted powder molded body is obtained by pressure molding a raw material powder containing a soft magnetic powder. The compacted powder molded body can have a higher content ratio of the soft magnetic powder in the molded body compared to the molded body of the composite material. A compacted powder molded body with a high content ratio of the soft magnetic powder has a high magnetic permeability. The content ratio of the soft magnetic powder in the compacted powder molded body is, for example, more than 80% by volume, 85% by volume or more, 90% by volume or more, or 95% by volume or more when the compacted powder molded body is 100% by volume. The above raw material powder may contain a lubricant.

[0061] <Embodiment 2> Referring to FIGS. 7 and 8, the reactor 1β of Embodiment 2 will be described. The reactor 1β of Embodiment 2 is different from the reactor 1α of Embodiment 1 in the shape of the magnetic core 8, the shape of the first holding member 5, and the shape of the second holding member 6.

[0062] As shown in FIG. 7, the outer core portion 82 of this example includes a first end core portion 821, a second end core portion 822, and two side core portions 823 and 824. The two side core portions 823 and 824 are arranged so as to sandwich the winding portion 20. The side core portion 823 connects the first end portions in the second direction D2 of the first end core portion 821 and the second end core portion 822, respectively. The side core portion 824 connects the second end portions in the second direction D2 of the first end core portion 821 and the second end core portion 822, respectively. The shape of the outer core portion 82 to which the first end core portion 821, the second end core portion 822, and the two side core portions 823 and 824 are connected is a rectangular ring shape when viewed from the third direction D3. Although not shown, the inner core portion of this example is connected to the central regions in the second direction D2 of the first end core portion 821 and the second end core portion 822, respectively.

[0063] Similar to Embodiment 1, the magnetic core 8 of this example is an integral molded product in which the inner core portion 81 and the outer core portion 82 are configured without joints. The magnetic core 8 of this example is composed of a molded body of a composite material.

[0064] As shown in FIGS. 7 and 8, the first holding member 5 of this example includes a main body portion 50, a first protrusion portion 51, a second protrusion portion 52, and two side portions 55, 56. The two side portions 55, 56 are arranged to face each other. The side portion 55 is provided so as to extend from the first end portion in the second direction D2 of the main body portion 50 in the first direction D1. The side portion 55 is disposed between the side core portion 823 and the winding portion 20. The surface of the side portion 55 facing the winding portion 20 is an arc surface along the outer shape of the winding portion 20. The side portion 56 is provided so as to extend from the second end portion in the second direction D2 of the main body portion 50 in the first direction D1. The side portion 56 is disposed between the side core portion 824 and the winding portion 20. The surface of the side portion 56 facing the winding portion 20 is an arc surface along the outer shape of the winding portion 20. A gap 7 is provided between the side portion 55 and the winding portion 20 and between the side portion 56 and the winding portion 20, as shown in FIG. 8 for example.

[0065] Similar to the first holding member 5, the second holding member 6 of this example includes a main body portion 60, a first protrusion portion, a second protrusion portion, and two side portions 65, 66. The first protrusion portion and the second protrusion portion are the same as the first protrusion portion 61 and the second protrusion portion 62 shown in FIGS. 2 and 3. The second holding member 6 of this example coincides with the first holding member 5 when rotated 180° around an axis parallel to the second direction D2.

[0066] Also in this example, since there are two protrusion portions provided on the first holding member 5, namely the first protrusion portion 51 and the second protrusion portion 52, the number of objects to be inspected for the moldability of the protrusion portions is small. Even though the number of protrusion portions provided on the first holding member 5 is two, since the first protrusion portion 51 corresponds to the first curved portion 43 and the second protrusion portion 52 corresponds to the second curved portion 44, it is easy to increase the rigidity of the first protrusion portion 51 and the second protrusion portion 52. The first holding member 5 having the first protrusion portion 51 and the second protrusion portion 52 with high rigidity is excellent in rigidity.

[0067] Similarly, since the protruding portions provided on the second holding member 6 are two, namely the first protruding portion and the second protruding portion, the number of objects to be inspected for the moldability of the protruding portions is small. Even if the number of protruding portions provided on the second holding member 6 is two, since the first protruding portion 61 corresponds to the first curved portion 43 and the second protruding portion 62 corresponds to the second curved portion 44, it is easy to increase the rigidity of the first protruding portion 61 and the second protruding portion 62. The second holding member 6 having the first protruding portion 61 and the second protruding portion 62 with high rigidity is excellent in rigidity.

[0068] <Embodiment 3> Referring to FIGS. 9 to 13, the reactor 1γ of Embodiment 3 will be described. The reactor 1γ of Embodiment 3 includes two winding portions 20. The reactor 1γ of Embodiment 3 is different from the reactor 1α of Embodiment 1 in the number of winding portions 20, the shape of the magnetic core 8, the shape of the first holding member 5, and the shape of the second holding member 6.

[0069] The coil 2 in this example includes two winding portions 20. The two winding portions 20 have the same configuration. The two winding portions 20 are composed of a single winding wire 3. Although not shown, the first ends of both winding portions 20 are connected to each other. Each winding portion 20 is composed of a plurality of turns 4. In any of the winding portions 20, each turn 4 is composed of a first straight portion 41, a first curved portion 43, a second straight portion 42, and a second curved portion 44 arranged in order around the axis of the winding portion 20 as shown in FIG. 12. The configuration of each winding portion 20 is the same as the configuration of the winding portion 20 described in Embodiment 1.

[0070] The magnetic core 8 in this example includes two inner core portions 81 shown in FIG. 13 and an outer core portion 82 shown in FIG. 9. Similar to Embodiment 1, the magnetic core 8 in this example is an integral molded product in which the two inner core portions 81 and the outer core portion 82 are configured without joints. The magnetic core 8 in this example is composed of a molded body of a composite material. In FIG. 13, the outer core portion 82 shown in FIG. 9 is not shown for easy understanding.

[0071] The two inner core portions 81 have the same configuration. At both ends of each inner core portion 81, as shown in FIG. 13, two recesses 810 are provided. The two recesses provided at the first end of the inner core portion 81 are provided corresponding to the first protrusion 51 and the second protrusion 52 provided on the first holding member 5. In FIG. 13, for convenience of explanation, a state where the first holding member 5 is assembled to the first end of the inner core portion 81 is shown. The two recesses 810 provided at the second end of the inner core portion 81 are provided corresponding to the first protrusion 61 and the second protrusion 62 provided on the second holding member 6 shown in FIGS. 10 and 11.

[0072] As shown in FIG. 9, the outer core portion 82 of this example includes a first end core portion 821 and a second end core portion 822. The first end of each inner core portion 81 is connected to the first end core portion 821, and the second end of each inner core portion 81 is connected to the second end core portion 822. The shape of the magnetic core 8 in which the two inner core portions 81 and the outer core portion 82 are connected is a rectangular O shape when viewed from the third direction D3.

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

[0074] The side portion 55 is provided between the two through holes 50h. As shown in FIG. 9, the side portion 55 is disposed between the two winding portions 20. The surface of the side portion 55 facing the winding portion 20 is an arc surface along the outer shape of the winding portion 20. A gap 7 is provided between the side portion 55 and each winding portion 20, as shown in FIG. 12 for example.

[0075] The second holding member 6 of this example includes a main body portion 60, a first protrusion portion 61, a second protrusion portion 62, and a side portion 65, similar to the first holding member 5. The second holding member 6 of this example coincides with the first holding member 5 when rotated 180° around an axis parallel to the second direction D2.

[0076] In this example, although the reactor 1γ includes two winding portions 20, since the protrusion portions provided for the first end portion of one winding portion 20 in the first holding member 5 are two, namely the first protrusion portion 51 and the second protrusion portion 52, the number of objects to be inspected for the moldability of the protrusion portions is small. Even if the number of protrusion portions provided for the first end portion of one winding portion 20 is two, since the first protrusion portion 51 corresponds to the first curved portion 43 and the second protrusion portion 52 corresponds to the second curved portion 44, it is easy to increase the rigidity of the first protrusion portion 51 and the second protrusion portion 52. The first holding member 5 having the first protrusion portion 51 and the second protrusion portion 52 with high rigidity is excellent in rigidity.

[0077] Similarly, since the protrusion portions provided for the second end portion of one winding portion 20 in the second holding member 6 are two, namely the first protrusion portion 61 and the second protrusion portion 62, the number of objects to be inspected for the moldability of the protrusion portions is small. Even if the number of protrusion portions provided for the second end portion of one winding portion 20 is two, since the first protrusion portion 61 corresponds to the first curved portion 43 and the second protrusion portion 62 corresponds to the second curved portion 44, it is easy to increase the rigidity of the first protrusion portion 61 and the second protrusion portion 62. The second holding member 6 having the first protrusion portion 61 and the second protrusion portion 62 with high rigidity is excellent in rigidity.

[0078] <Embodiment 4> ≪Converter · Power Conversion Device≫ The above reactors 1α, 1β, and 1γ can be used for applications that meet the following energization conditions. Examples of the energization conditions include a maximum direct current of about 100 A or more and 1000 A or less, an average voltage of about 100 V or more and 1000 V or less, and an operating frequency of about 5 kHz or more and 100 kHz or less. The above reactors 1α, 1β, and 1γ are typically used as components of a converter mounted on vehicles such as electric vehicles and hybrid vehicles, or as components of a power conversion device equipped with this converter.

[0079] Vehicles 1200 such as hybrid vehicles and electric vehicles include a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and a motor 1220 that is driven by the power supplied from the main battery 1210 and used for running, as shown in FIG. 14. The motor 1220 is typically a three-phase AC motor that drives the wheels 1250 during running 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. 14, the charging point of the vehicle 1200 is an inlet, but it may also be in a form equipped with a plug.

[0080] The power conversion device 1100 includes a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 for converting between DC and AC. The converter 1110 shown in this example boosts the input voltage of the main battery 1210, which is about 200 V or more and 300 V or less, to about 400 V or more and 700 V or less during the running of the vehicle 1200 and supplies power to the inverter 1120. During regeneration, the converter 1110 steps down 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. The inverter 1120 converts the DC boosted by the converter 1110 into a predetermined AC and supplies power to the motor 1220 during the running of the vehicle 1200, and converts the AC output from the motor 1220 into DC and outputs it to the converter 1110 during regeneration.

[0081] As shown in FIG. 15, the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor 1115, and converts the input voltage by repeating ON / OFF. Here, the conversion of the input voltage means performing step-up and step-down. As the switching element 1111, a power device such as a field effect transistor or an insulated gate bipolar transistor is used. The reactor 1115 utilizes the property of a coil that attempts to prevent changes in the current flowing through the circuit, and has a function of smoothing the change when the current attempts to increase or decrease due to the switching operation. The reactor 1115 includes the reactors 1α, 1β, and 1γ described above.

[0082] In addition to the converter 1110, the vehicle 1200 includes a power supply converter 1150 connected to the main battery 1210, and a sub-battery 1230 that serves as a power source for auxiliary devices 1240 and a converter 1160 for auxiliary power supply connected to the main battery 1210, which converts the high voltage of the main battery 1210 into a low voltage. The converter 1110 typically performs DC-DC conversion, while the power supply converter 1150 and the converter 1160 for auxiliary power supply perform AC-DC conversion. Some of the power supply converters 1150 perform DC-DC conversion. The reactors of the power supply converter 1150 and the converter 1160 for auxiliary power supply have the same configuration as the reactors 1α, 1β, and 1γ described above, and reactors with appropriately changed sizes and shapes can be used. Also, the reactors 1α, 1β, and 1γ described above can be used in a converter that performs conversion of input power and only performs step-up or only performs step-down.

Description of Reference Numerals

[0083] 1α, 1β, 1γ Reactors 2 Coil 20 Winding Portion 21 First End Face 22 Second End Face 3 Winding 4 Turn 41 First Straight Portion 42 Second straight portion 43 First curved portion 44 Second curved portion 5 First holding member 50 Main body portion 50h Through hole 51 First protrusion 52 Second protrusion 55, 56 Side portions 6 Second holding member 60 Main body portion 60h Through hole 61 First protrusion 62 Second protrusion 65, 66 Side portions 7 Gap 8 Magnetic core 81 Inner core portion 810 Recess 82 Outer core portion 821 First end core portion 822 Second end core portion 823, 824 Side core portions L1, L2 Lengths D1 First direction, D2 Second direction, D3 Third direction 1100 Power conversion device, 1110 Converter, 1111 Switching element 1112 Drive circuit, 1115 Reactor, 1120 Inverter 1150 Converter for power supply device, 1160 Converter for auxiliary power supply 1200 Vehicle, 1210 Main battery, 1220 Motor 1230 Sub - battery, 1240 Auxiliary equipment, 1250 Wheel, 1300 Engine

Claims

1. A coil having a winding portion composed of windings of a plurality of turns, a first holding member disposed so as to face a first end surface of the winding portion, a second holding member disposed so as to face a second end surface of the winding portion, and comprising: each of the plurality of turns is composed of a first straight portion, a first curved portion, a second straight portion, and a second curved portion arranged in order around the axis of the winding portion, each of the first holding member and the second holding member includes two protrusions for positioning the winding portion, the two protrusions are composed of a first protrusion that contacts at least a part of the first curved portion and a second protrusion that contacts at least a part of the second curved portion, a reactor.

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

3. The reactor according to claim 1, wherein each of the first protrusion and the second protrusion has a shape along the inner peripheral shape of the winding portion.

4. The reactor according to claim 1, wherein the coil is an edge-wound coil composed of flat wires.

5. The reactor according to claim 1, wherein a first length of each of the first straight portion and the second straight portion is longer than a second length between the first straight portion and the second straight portion.

6. Comprising the reactor according to any one of claims 1 to 5, a converter.

7. Comprising the converter according to claim 6, a power conversion device.

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