Reactor

Abstract

To provide a reactor with suppressed vibration of individual assemblies.SOLUTION: A reactor includes a coil assembly having a coil, a first split core assembly having a first split core constituting an annular core containing a magnetic body, a second split core assembly having a second split core constituting the annular core, a joint where the first split core assembly and the second split core assembly are butted together, and adhesive for bonding the joint. The coil assembly, the first split core assembly, and the second split core assembly each have one fixing portion for external attachment. The coil assembly has a protrusion that protrudes toward the joint. The adhesive leaks from the joint and adheres to the protrusion, bonding the coil assembly, the first split core assembly, and the second split core assembly together.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present invention relates to a reactor including a coil and a core. [Background technology]

[0002] A reactor is an electromagnetic component that converts electrical energy into magnetic energy, stores it, and releases it. Reactors are used in a wide variety of applications. Typical reactors include boost reactors, series reactors, parallel reactors, current-limiting reactors, starting reactors, shunt reactors, neutral reactors, and arc-suppression reactors.

[0003] Boost reactors are incorporated into onboard boost circuits such as those found in the drive systems of hybrid and electric vehicles. Series reactors are connected in series to motor circuits to limit current during short circuits. Parallel reactors stabilize current sharing between parallel circuits. Current-limiting reactors limit current during short circuits and are connected to them. Starting reactors are connected in series to motor circuits to protect the machine and limit starting current. Shunt reactors are connected in parallel to transmission lines to compensate for leading reactive power and suppress abnormal voltages. Neutral reactors are connected between the neutral point and the ground to limit the ground fault current that flows in the event of a ground fault in the power system. Arc-suppression reactors automatically extinguish the arc that occurs when a single-phase ground fault occurs in a three-phase power system.

[0004] A reactor mainly consists of a coil and a toroidal core. When an external current is applied to the coil, it generates a magnetic flux according to the number of turns, and functions as an inductive reactance. The toroidal core contains a magnetic material and forms a closed magnetic circuit through which the magnetic flux generated by the coil passes with a magnetic permeability higher than that of a vacuum. For convenience in assembling the reactor, the toroidal core is manufactured in two parts: a first divided core and a second divided core; after the coil is inserted, the first divided core and the second divided core are joined together.

[0005] The coil, first split core, and second split core are covered with a coating resin, for example by molding or attachment, to protect them from physical contact and to provide a fixing portion for mounting the reactor. The coating resin has a fixing portion with an embedded collar for passing a fastener such as a bolt. An assembly including this coating resin, fixing portion, and coil is called a coil assembly. An assembly including the coating resin, fixing portion, and first split core is called a first split core assembly. An assembly including the coating resin, fixing portion, and second split core is called a second split core assembly.

[0006] The fixing parts for fastening the mounting board and the reactor may be arranged in one location each on the coil assembly, the first split core assembly, and the second split core assembly (see, for example, Patent Document 1). This is to reduce the number of fixing parts, which are a factor in increasing the size of the reactor, and to secure space in line with the recent trend toward greater integration of electronic and electrical components and miniaturization of modules. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent No. 6362904 Summary of the Invention [Problem to be solved by the invention]

[0008] The coil assembly, the first split core assembly, and the second split core assembly are not a single rigid body. Furthermore, when a fixing portion is provided on each of the coil assembly, the first split core assembly, and the second split core assembly, and the reactor is mounted on a mounting board, each is fixed in a cantilever structure. In such a reactor, the coil assembly, the first split core assembly, and the second split core assembly are prone to vibrating individually. This vibration can cause vibration noise from the reactor and fluctuate the reactor's inductance.

[0009] The present invention has been proposed to solve the above-mentioned problems, and an object of the present invention is to provide a reactor in which vibration of each assembly is suppressed. [Means for solving the problem]

[0010] In order to achieve the above-mentioned object, a reactor according to an embodiment of the present invention comprises a coil assembly having a coil, a first split core assembly having a first split core which is a constituent part of an annular core containing a magnetic material, a second split core assembly having a second split core which is a constituent part of the annular core, a joint where the first split core assembly and the second split core assembly are butted together, and an adhesive for bonding the joint, wherein the coil assembly, the first split core assembly and the second split core assembly each have one fixing portion for external attachment, the coil assembly has a protrusion that protrudes toward the joint, and the adhesive adheres from the joint to the protrusion, bonding the coil assembly, the first split core assembly and the second split core assembly together.

[0011] The coil assembly may have a coating resin that coats the coil, and the protrusion may protrude from the coating resin.

[0012] The joint may have an end of the first split core, an end of the second split core, and a spacer interposed between the two ends, and the tip of the protrusion may extend toward the spacer, and the thickness of the tip may be more than half the thickness of the spacer.

[0013] The protrusion may extend into a region between an end face of the first divided core and an end face of the second divided core, and protrude close to the spacer.

[0014] The protrusion may have foot portions on both sides of the tip end that are close to the side wall portions of the end of the first divided core and the side wall portions of the end of the second divided core.

[0015] The protrusion may have a shape that follows the outer shape of the joint including the side wall.

[0016] The corners of the first divided core and the corners of the second divided core may have a rounded shape. [Effects of the Invention]

[0017] According to the present invention, it is possible to suppress vibrations occurring in the individual assemblies that constitute the reactor. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 2 is a perspective view showing the main configuration of a reactor. [Figure 2] FIG. 2 is a perspective view showing the appearance of a reactor. [Figure 3] FIG. 2 is an exploded view of the reactor. [Figure 4] FIG. 2 is a top view of a first divided core assembly and a second divided core assembly. [Figure 5] FIG. [Figure 6] FIG. 2 is a cross-sectional perspective view of a reactor. [Figure 7] FIG. [Figure 8] FIG. 6 is an enlarged view of the vicinity of a joint provided in the reactor of the second embodiment. [Figure 9] FIG. 10 is an enlarged view of the vicinity of a joint provided in the reactor of the third embodiment. [Figure 10] FIG. 10 is an enlarged view of the vicinity of a joint provided in the reactor of the fourth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0019] Hereinafter, reactors according to embodiments of the present invention will be described with reference to the drawings. In each drawing, thickness, dimensions, positional relationships, ratios, shapes, etc. may be exaggerated for ease of understanding, but the present invention is not limited to such exaggeration.

[0020] 1 is a perspective view showing the main configuration of a reactor 1 according to a first embodiment, and for ease of explanation, the components covering each part are omitted. The reactor 1 includes an annular core 7 and a coil 21. The coil 21 is attached to the annular core 7. The reactor 1 is an electromagnetic component that converts electrical energy into magnetic energy and stores and releases the energy.

[0021] That is, coil 21 is a cylindrically wound conductive wire with an insulating coating such as enamel coating. Coil 21 is formed by spirally winding the wire along the winding axis while shifting the winding position for each turn. The conductive wire of coil 21 is, for example, a rectangular wire, and coil 21 is a spiral edgewise coil formed by winding the conductive wire so that the wide surface of the conductive wire extends in a direction perpendicular to the winding axis of coil 21. For example, a flatwise coil can also be used as coil 21. Coil 21 is an inductor that generates magnetic flux according to the number of turns when current is applied from a circuit in which reactor 1 is incorporated, and introduces inductive reactance into the circuit.

[0022] The annular core 7 includes a magnetic material such as a powder magnetic core, a ferrite magnetic core, a metal composite core, or a laminated steel plate. A powder magnetic core is a compact formed by compressing magnetic powder and then annealing it. The magnetic powder is primarily composed of iron, and examples thereof include pure iron powder, iron-based permalloy (Fe-Ni alloy), Si-containing iron alloy (Fe-Si alloy), sendust alloy (Fe-Si-Al alloy), or a mixture of two or more of these powders. The magnetic powder may be an amorphous alloy or a nanocrystalline alloy powder. A metal composite core is a core formed by kneading and molding magnetic powder and resin. This annular core 7 forms a closed magnetic circuit through which the magnetic flux generated by the coil 21 passes with a magnetic permeability higher than that of a vacuum.

[0023] Fig. 2 is a perspective view showing the appearance of the reactor 1, and Fig. 3 is an exploded view of the reactor 1. As shown in Figs. 2 and 3, the reactor 1 includes a coil assembly 2, a first split core assembly 3, and a second split core assembly 4. The coil assembly 2 is an assembly (ASSY) that includes a coil 21. The first split core assembly 3 is an assembly that includes a first split core 31, and the second split core assembly 4 is an assembly that includes a second split core 41.

[0024] Here, the first divided core 31 and the second divided core 41 are components of the annular core 7 and have a U-shape. The annular core 7 is divided into the first divided core 31 and the second divided core 41, which are joined together to form an annular shape. In order to insert the coil 21 into the annular core 7, the annular core 7 is divided into the first divided core 31 and the second divided core 41. After the coil 21 is inserted, the first divided core 31 and the second divided core 41 are joined together to form the annular core 7.

[0025] The coil assembly 2 has a coil 21, a coating resin 22, and a fixing portion 2a. By coating the coil 21, the coating resin 22 protects the coil 21 from mechanical shock and also insulates the coil 21 from the annular core 7. The fixing portion 2a is formed in one location on the coating resin 22 and protrudes from the coating resin 22 in the shape of a tab, for example. This fixing portion 2a has a through-hole into which a bolt, screw, or pin is inserted, and serves as a first fastening portion when attaching the reactor 1.

[0026] The first split core assembly 3 has a first split core 31, a coating resin 32, and a fixing portion 3a. The coating resin 32 covers the first split core 31, thereby protecting the first split core 31 from mechanical shock. The fixing portion 3a is formed in one location on the coating resin 32 and protrudes from the coating resin 32 in the shape of a tab, for example. The fixing portion 3a has a through hole into which a bolt, screw, or pin is inserted, and serves as a second fastening portion when installing the reactor 1.

[0027] The second split core assembly 4 has a second split core 41, a coating resin 42, and a fixing portion 4a. The coating resin 42 covers the second split core 41, thereby protecting the second split core 41 from mechanical shock. The fixing portion 4a is formed in one location on the coating resin 42 and protrudes from the coating resin 42 in the shape of a tab, for example. This fixing portion 4a has a through hole into which a bolt, screw, or pin is inserted, and serves as a third fastening portion when installing the reactor 1.

[0028] It is preferable that the fixed portions 2a, 3a and 4a of the coil assembly 2, the first split core assembly 3 and the second split core assembly 4 extend in a distributed manner on three sides of the reactor 1 to ensure stability when the reactor 1 is installed.

[0029] For example, the fixed portion 2a of the coil assembly 2 extends from near the center position along the winding axis of the coil 21. The fixed portions 3a and 4a of the first and second split core assemblies 3 and 4 extend to the opposite side from the fixed portion 2a of the coil assembly 2, sandwiching the coil 21 between them. The fixed portion 3a of the first split core assembly 3 extends to the position of one yoke 7a of the annular core 7, and the fixed portion 4a of the second split core assembly 4 extends to the position of the other yoke 7b of the annular core 7, and the fixed portions 3a and 4a are spaced apart, sandwiching the coil 21 between them.

[0030] The yokes 7a and 7b are paths on a magnetic circuit that connect the legs 7c and 7d of the annular core 7, on which the coil 21 is attached. The yoke 7a is provided on the first split core 31, which belongs to the first split core assembly 3. The yoke 7b is provided on the second split core 41, which belongs to the second split core assembly 4.

[0031] Here, the portions of legs 7c, 7d that are not at the base and near yokes 7a, 7b are referred to as end portions 33, 43. The tips of end portions 33, 43 are referred to as end faces 33a, 43a. The peripheral surfaces of end portions 33, 43, which are perpendicular to end faces 33a, 43a and extend along the length of legs 7c, 7d, are referred to as side wall portions 33b, 43b. The corners that form the boundaries between end faces 33a, 43a and side wall portions 33b, 43b are referred to as corner portions 34, 44.

[0032] The coating resin 22, coating resin 32 and coating resin 42 of the coil assembly 2, the first split core assembly 3 and the second split core assembly 4 are, for example, epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Terephthalate), or a composite of these, and are insulating and heat-resistant, and may contain a thermally conductive filler.

[0033] 4 is a top view of the first split core assembly 3 and the second split core assembly 4. As shown in FIG. 4, the first split core 31 and the second split core 41 are joined together by butting the U-shaped ends 33 and 43 together to form an annular shape. That is, the annular core 7 has a joint 5. The joint 5 has the end 33 of the first split core 31 and the end 43 of the second split core 41.

[0034] At the joint 5, the end 33 of the first divided core 31 and the end 43 of the second divided core 41 may be in direct contact. Alternatively, the joint 5 may further include a spacer 51, and the end 33 of the first divided core 31 and the end 43 of the second divided core 41 may be joined via the spacer 51. The spacer 51 is a magnetic gap that prevents a decrease in inductance, and is made of a non-magnetic material, ceramic, non-metal, resin, carbon fiber, or a composite material of two or more of these, or gap paper.

[0035] The coating resin 32 of the first split core assembly 3 and the coating resin 42 of the second split core assembly 4 cover the first split core 31 and the second split core 41, excluding at least the joint 5. In other words, the joint 5 is exposed from the coating resin 32 of the first split core assembly 3 and the coating resin 42 of the second split core assembly 4.

[0036] Preferably, of the joint portion 5, not only the end face 33a of the first split core 31 facing the second split core 41 but also the side wall portion 33b of the end portion 33 of the first split core 31 are exposed from the coating resin 32 of the first split core assembly 3. Also, not only the end face 43a of the second split core 41 facing the first split core 31 but also the side wall portion 43b of the end portion 43 of the second split core 41 are exposed from the coating resin 42 of the second split core assembly 4. As described above, the side wall portion 33b is a peripheral surface around the end portion 33 that is perpendicular to the end face 33a and extends along the longitudinal direction of the legs 7c and 7d, and the side wall portion 43b is a peripheral surface around the leg 43 that is perpendicular to the end face 43a and extends along the longitudinal direction of the legs 7c and 7d. The side wall portion 33b of the end portion 33 of the first split core 31 and the side wall portion 43b of the end portion 43 of the two split cores 41 may be exposed not only all around but also on some of their four sides.

[0037] Furthermore, the coating resin 32 of the first split core assembly 3 and the coating resin 42 of the second split core assembly 4 are sufficient to expose at least the joint portion 5 and to cover at least the portion of the annular core 7 that protrudes from the coil assembly 2.

[0038] Fig. 5 is a cross-sectional view of the coil assembly 2. As shown in Fig. 5, the coating resin 22 of the coil assembly 2 covers the coil 21. To insulate the coil from the annular core 7, the coating resin 22 covers the entire area facing the annular core 7, i.e., the entire length and one revolution of the inner circumferential surface of the coil 21. To protect the coil from external mechanical shocks, the coating resin 22 covers the entire length and one revolution of the outer circumferential surface of the coil 21, and also covers the end faces of the coil 21.

[0039] The coating resin 22 of this coil assembly 2 has a cylindrical portion 23 formed by covering the inner peripheral surface of the coil 21. A protrusion 24 is provided on the inner surface of the cylindrical portion 23. The protrusion 24 is formed seamlessly and integrally with the coating resin 22 and extends from the coating resin 22. FIG. 6 is a cross-sectional perspective view of the reactor 1, showing the state in which the coil assembly 2 is attached to the first split core assembly 3 and the second split core assembly 4. As shown in FIGS. 5 and 6, the protrusion 24 protrudes toward the joint 5 of the annular core 7.

[0040] This protrusion 24 has a tip portion 25. The tip portion 25 enters the area sandwiched between the end face 33a of the first divided core 31 and the end face 43a of the second divided core 41, extends toward the spacer 51, and is close to the spacer 51 with a small gap between them. The thickness of the tip portion 25 is at least half the thickness of the spacer 51 but less than the same thickness. The thickness is the length along the longitudinal direction of the tubular portion 23. Less than the same thickness means that the tip portion 25 is not in contact with the end face 33a of the first divided core 31 or the end face 43a of the second divided core 41.

[0041] The protrusion 24 further includes a foot portion 26. The foot portions 26 protrude from both sides of the tip portion 25, i.e., from the longitudinal direction of the tubular portion 23, so as to sandwich the tip portion 25. In this way, the protrusion 24 has a shape in which the tip portion 25 and both foot portions 26 are seamlessly integrated into one piece. The foot portion 26 adjacent to the first split core 31 extends toward the side wall portion 33b of the end portion 33 of the first split core 31 and is close to the side wall portion 33b with a small gap therebetween. The foot portion 26 adjacent to the second split core 41 extends toward the side wall portion 43b of the end portion 43 of the second split core 41 and is close to the side wall portion 43b with a small gap therebetween.

[0042] From the end of one foot portion 26 past the tip portion 25 to the end of the other foot portion 26, the creeping surface 27 of the protrusion 24 facing the joint 5 follows the external shape of the joint 5, and a small gap continues between the joint 5 and the entire creeping surface 27 of the protrusion 24. When the corner 34 between the end face 33a and the side wall portion 33b is chamfered to form a rounded corner, and when the corner 44 between the end face 43a and the side wall portion 43b is chamfered to form a rounded corner, the creeping surface 27 of the protrusion 24 smoothly widens following the curvature of the corners 34 and 44.

[0043] In such a coil assembly 2, first split core assembly 3, and second split core assembly 4, as shown in Figure 3, when the first split core assembly 3 is inserted into the coil assembly 2, the second split core assembly 4 is inserted into the coil assembly 2 from the opposite side of the first split core assembly 3, rather than inserting both the first split core assembly 3 and the second split core assembly 4 into the coil assembly 2 from the opposite side of the first split core assembly 3. By assembling the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 in this manner, the reactor 1 can be formed. Furthermore, a spacer 51 is interposed between the first split core 31 and the second split core 41, and the end 33 of the first split core 31 and the end 43 of the second split core 41 are butted together inside the coil assembly 2.

[0044] 7 is an enlarged view of the vicinity of the joint 5. As shown in FIG. 7, adhesive 6 is applied between the end 33 of the first split core 31 and the spacer 51, and between the end 43 of the second split core 41 and the spacer 51. When the end 33 of the first split core 31 and the end 43 of the second split core 41 are butted together with the spacer 51 interposed therebetween, the adhesive 6 also leaks out between the protrusion 24 of the coil assembly 2 and the joint 5. In other words, the amount of adhesive 6 applied is adjusted so that the adhesive 6 also leaks out between the protrusion 24 of the coil assembly 2 and the joint 5.

[0045] This adhesive 6 not only bonds the first split core assembly 3 and the second split core assembly 4 together, but also joins the coil assembly 2 to the first split core assembly 3 and the second split core assembly 4. In other words, the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 are joined by the joints 5 and the protrusions 24 to form a single rigid body.

[0046] When the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 become a single rigid body, the single rigid body made up of the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 is supported on the mounting board at three fixing portions 2a, 3a, and 4a, eliminating the cantilever structure. As a result, independent vibrations of the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 are suppressed.

[0047] Thus, this reactor 1 includes a coil assembly 2 having a coil 21, a first split core assembly 3 having a first split core 31 which is a component of an annular core 7 including a magnetic body, and a second split core assembly 4 having a second split core 41 which is a component of the annular core 7. The reactor 1 also includes a joint 5 where the first split core assembly 3 and the second split core assembly 4 are butted together, and an adhesive 6 which bonds the joint 5.

[0048] The coil assembly 2, the first split core assembly 3, and the second split core assembly 4 each have one fixing portion 2a, 3a, and 4a for external attachment. The coil assembly 2 has a protrusion 24 that protrudes toward the joint 5, and the adhesive 6 adheres from the joint 5 to the protrusion 24, bonding the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 together.

[0049] As a result, the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 are joined by the joint 5 and the protrusion 24 to form a single rigid body. Therefore, the cantilever structure of the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 is eliminated, and vibrations generated by the reactor 1 are suppressed.

[0050] Incidentally, the coil assembly 2 has the coating resin 22 that coats the coil 21, and the protrusion 24 protrudes from this coating resin 22 toward the joint 5, but this is not limited to this. The coil assembly 2 may be provided with the protrusion 24 that is a separate member from the coating resin 22, and this protrusion 24 may protrude toward the joint 5. However, the condition is that the separate member and the coating resin 22 are fixed together.

[0051] Furthermore, the annular core 7 may be divided into at least two or more pieces. That is, the reactor 1 may include another core assembly including a split core in addition to the first split core assembly 3 and the second split core assembly 4. If the protrusion 24 of the coil assembly 2 protrudes toward at least the joint 5 between the first split core assembly 3 and the second split core assembly 4, the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 become a single rigid body, and vibrations generated in the reactor 1 can be suppressed to the extent that there are fewer independent assemblies. Of course, it is also possible to have each protrusion 24 protrude toward each joint 5 of all core assemblies, and all assemblies become a single rigid body.

[0052] A single reactor 1 may also include a plurality of coil assemblies 2. Each of the coil assemblies 2 includes a protrusion 24. When two coil assemblies 2 are included, the protrusion 24 may protrude toward the joints 5 included in the attached legs 7c, 7d and the legs 7c, 7d of another coil assembly 2. When three coil assemblies 2 are included, the protrusion 24 may protrude toward the joints 5 included in the attached legs 7c, 7d, the legs 7c, 7d of another coil assembly 2, and the legs 7c, 7d of yet another coil assembly 2. When a plurality of coil assemblies 2 are included, the protrusion 24 may protrude toward the joints 5 included in the legs 7c, 7d of each of the attached coil assemblies 2. For example, the two coils 21 shown in FIG. 1 are connected in series and operate as a single linked coil. However, the present invention is not limited to this. Separate coils 21 may be formed from two identical electric wires, and each may be separated into two independent coil assemblies 2.

[0053] From the viewpoint of joining strength, it is most preferable that the protrusion 24 be annular and protrude around the entire inner circumference of the tubular portion 23, but this is not limitative and the protrusion 24 may protrude from a partial range of the inner circumference of the tubular portion 23, and the vibration reduction effect can be obtained.

[0054] Furthermore, one coil assembly 2 including a linked coil in which two coils 21 are connected in series, or one coil assembly 2 including multiple independent coils 21, is attached to multiple legs 7c, 7d and has multiple tubular portions 23. In this case, it is most preferable from the standpoint of joint strength that the protrusions 24 protrude from all of the tubular portions 23, but even if the protrusions 24 are made to protrude from some of the tubular portions 23, the coil assembly 2, first split core assembly 3, and second split core assembly 4 will form a single rigid body.

[0055] Furthermore, in this reactor 1, the joint 5 includes the end 33 of the first split core 31, the end 43 of the second split core 41, and a spacer 51 interposed between the end portions 33, 43. The tip 25 of the protrusion 24 extends toward the spacer 51, and the thickness of the tip 25 is at least half the thickness of the spacer 51. This increases the joint strength and provides an effect of suppressing vibration from the reactor 1. In other words, if the thickness of the tip 25 is less than half the thickness of the spacer 51, the strength of the protrusion 24 will decrease, the amount of adhesive 6 will increase, and the effect of suppressing vibration from the reactor 1 will be reduced.

[0056] Furthermore, in this reactor 1, the protrusion 24 has foot portions 26 on both sides of the tip 25 that are close to the side wall portions 33b of the end 33 of the first split core 31 and the side wall portions 43b of the end 43 of the second split core 41. This increases the bonding area of ​​the coil assembly 2 to the first split core assembly 3 and the second split core assembly 4, increasing the bonding strength. This results in a single, firmly bonded rigid body, improving the vibration suppression effect of the reactor 1.

[0057] Furthermore, in this reactor 1, the protrusion 24 has a shape that follows the outer shape of the joint 5 including the side wall portions 33b and 43b. This allows the protrusion 24 and the joint 5 to adhere to each other via the adhesive 6, increasing the joint strength. This results in a single, strongly bonded rigid body, improving the vibration suppression effect of the reactor 1. Note that a portion of the area between the protrusion 24 and the joint 5 may adhere to each other via the adhesive 6, and the protrusion 24 and the joint 5 may also adhere directly to each other in part, which will still be effective.

[0058] Furthermore, in this reactor 1, the corners 34 of the first divided core 31 and the corners 44 of the second divided core 41 are rounded. This increases the distance between the protrusion 24 and the joint 5, increasing the joint strength. This results in a single, firmly joined rigid body, improving the vibration suppression effect of the reactor 1.

[0059] 8 is an enlarged view showing a second embodiment of the joint 5 of the reactor 1, but the corners 34 of the first split core 31 and the corners 44 of the second split core 41 may be right angles without being chamfered. Even in this case, the protrusions 24 have at least the tip portions 25 that protrude toward the spacer 51, so that the protrusions 24 are joined to the joint 5 with the adhesive 6, and the coil assembly 2, the first split core assembly 3, and the second split core assembly 4 form a single rigid body. Also, the corners 34 of the first split core 31 and the corners 44 of the second split core 41 may be cut off instead of rounded, which increases the creepage distance 27 as with rounded corners.

[0060] 9 and 10 are enlarged views showing third and fourth embodiments of the joint 5 of the reactor 1, but the end face 33 a of the first split core 31 and the end face 43 a of the second split core 41 may be in direct contact with each other without the interposition of the spacer 51. In this case, too, the protrusion 24 may be made to protrude toward the joint 5 between the first split core 31 and the second split core 41, and any adhesive 6 leaking from the joint 5 may be adhered to the protrusion 24.

[0061] 9, the protrusion 24 may be formed to protrude into the gap formed by the rounded corner 34 of the first divided core 31 and the rounded corner 44 of the second divided core 41. Preferably, the creeping surface 27 may be formed to conform to the shape of the gap formed by the corners 34 and 44. Even if the corners of the corners 34 and 44 are cut off, it is still preferable that the creeping surface 27 be formed to conform to the shape of the gap formed by the corners 34 and 44.

[0062] 10 , even if the corner 34 of the first divided core 31 and the corner 44 of the second divided core 41 are right angles and the joint 5 is flat, the protrusion 24 may be made to protrude toward the joint 5. The protrusion 24 is spread along the side wall 33b of the first divided core 31 and the side wall 43b of the second divided core 41. The adhesive 6 leaking out from between the end face 33a of the first divided core 31 and the end face 43a of the second divided core 41 spreads between the protrusion 24 and the side wall 33b, and between the protrusion 24 and the side wall 43b, joining the protrusion 24 to the joint 5.

[0063] The above-described embodiments of the present invention are presented as examples, and the present invention is not limited to the above-described embodiments. The above-described embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the scope of the invention. The embodiments and their modifications are included in the scope of the present invention. [Explanation of symbols]

[0064] 1 reactor 2 Coil assembly 2a Fixed part 21 Coil 22 Coating resin 23 Cylinder part 24 Protrusion 25 Tip 26 Foothills 27 Creepage 3 First split core assembly 3a Fixed part 31 First divided core 32 Coating resin 33 End 33a End face 33b Side wall part 34 Corner 4 Second split core assembly 4a Fixed part 41 Second divided core 42 Coating resin 43 End 43a End face 43b Side wall part 44 Corner 5 Joint 51 Spacer 6. Adhesive 7 Annular Core 7a, 7b York 7c, 7d legs

Claims

1. a coil assembly having a coil; a first divided core assembly having a first divided core which is a component part of an annular core including a magnetic body; a second split core assembly having a second split core that is a component part of the annular core; a joint portion where the first split core assembly and the second split core assembly are butted together; an adhesive that bonds the joint; Equipped with the coil assembly, the first split core assembly, and the second split core assembly each have one fixing portion for attachment to an external device; the coil assembly has a protrusion that protrudes toward the joint, the adhesive is applied from the joint portion to the protrusion portion, and bonds the coil assembly, the first split core assembly, and the second split core assembly together; A reactor characterized by the above.

2. the coil assembly has a coating resin that coats the coil, the protrusion protrudes from the coating resin; The reactor according to claim 1,

3. the joint portion includes an end portion of the first divided core, an end portion of the second divided core, and a spacer interposed between the end portions, a tip end of the protrusion extends toward the spacer, and the thickness of the tip end is equal to or greater than half the thickness of the spacer; The reactor according to claim 1,

4. the protrusion extends into a region between the end surfaces of the first divided core and the second divided core, and protrudes in the vicinity of the spacer; The reactor according to claim 3,

5. the protrusion has foot portions on both sides of the tip end thereof, the foot portions being close to the side wall portions of the end portions of the first divided core and the second divided core; The reactor according to claim 4,

6. the protrusion has a shape that follows the outer shape of the joint including the side wall portion; The reactor according to claim 5,

7. corners of the first divided core and the second divided core have rounded corner shapes; The reactor according to claim 6,

Images