Reactor

Abstract

The objective is to provide a reactor structure that allows for easier precision compared to a coil constructed with a single busbar. [Solution] The reactor 1 comprises a core 2 and a coil 3 fitted onto the core 2, wherein the coil 3 is composed of a plurality of welded busbars 23-25, 37-39.

Description

Technical Field

[0001] The present disclosure relates to a reactor.

Background Art

[0002] Conventionally, reactors have been used in noise filters and the like. Patent Document 1 below discloses a reactor having a coil wound with a flat wire.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a reactor under a large current, in order to improve heat resistance performance, it is conceivable to use a bus bar with a large surface area. However, if a coil is to be formed of a single bus bar, there is a deviation in position due to winding, making it difficult to maintain accuracy and leaving room for improvement.

[0005] The present disclosure has been completed based on the above circumstances, and an object thereof is to provide a reactor structure that is easier to achieve accuracy compared to the case where a coil is formed of a single bus bar.

Means for Solving the Problems

[0006] The reactor of the present disclosure includes a core and a coil externally fitted to the core, and the coil is formed of a plurality of bus bars joined by welding.

Effects of the Invention

[0007] According to the present disclosure, compared to the case where a coil is formed of a single bus bar, there is an advantage that the deviation in position due to winding is small and accuracy is easily achieved. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a perspective view of a reactor according to an embodiment. [Figure 2] Figure 2 is a perspective view of the core. [Figure 3] Figure 3 is a perspective view of the core block. [Figure 4] Figure 4 is a cross-sectional view taken along line AA in Figure 1. [Figure 5] Figure 5 is a perspective view of the first and second coils. [Figure 6] Figure 6 is an exploded perspective view of Figure 5. [Figure 7] Figure 7 shows the positional relationship between the folded-over member and the core. [Figure 8] Figure 8 is a perspective view showing another form of the coil. [Figure 9] Figure 9 is a perspective view of the first and second busbars. [Figure 10] Figure 10 is an exploded perspective view of the welding jig. [Figure 11] Figure 11 is a perspective view of the reactor. [Figure 12] Figure 12 is a perspective view of the first and second coils. [Figure 13] Figure 13 is an exploded perspective view of the first and second coils. [Figure 14] Figure 14 is a plan view of the reactor. [Modes for carrying out the invention]

[0009] [Description of Embodiments in this Disclosure] First, the embodiments of this disclosure will be listed and described. [1] The reactor of the present disclosure comprises a core and a coil fitted onto the core, the coil comprising a plurality of busbars welded together.

[0010] This configuration has the advantage that, compared to the case where the coil is formed by a single bus bar, the displacement of the position due to winding is less, and it is easier to achieve accuracy.

[0011] [2] In [1] above, the core may include a first core and a second core facing each other in parallel, and the coil may include a first coil externally fitted to the first core and a second coil externally fitted to the second core. When the coil is wound an even number of times, the folding members of the first coil and the second coil may be arranged on the core. This configuration can suppress the protrusion of the folding members with respect to the outer shape of the core, and improve the volume efficiency of the coil.

[0012] [3] In [1] above, the core may include a first core and a second core facing each other in parallel, and the coil may include a first coil externally fitted to the first core and a second coil externally fitted to the second core. When the coil is wound an odd number of times, the folding portions of the first coil and the second coil may be arranged in the gap between the first core and the second core. This configuration prevents the folding portions from protruding from the outer shape of the coil, and improves the volume efficiency of the coil.

[0013] [4] In [1] to [3] above, the core may include a molded portion made of a resin material. By providing the molded portion, the tolerance can be reduced by holding the core during manufacturing.

[0014] [5] In [4] above, the molded portion may include a mounting portion. By providing the mounting portion, fastening to other fastening portions becomes easier.

[0015] [Details of Embodiments of the Present Disclosure] Embodiments of the present disclosure are described below. This disclosure is not limited to these examples, but is indicated by the claims, and all modifications within the meaning and scope of the claims are intended to be included. In the drawings, some parts of the configuration may be exaggerated or simplified for illustrative purposes. Also, the dimensional ratios of the parts may differ in the drawings. In this specification, “orthogonal” includes not only strictly orthogonal but also approximately orthogonal to the extent that the function and effect of the present embodiment is achieved.

[0016] Furthermore, in this specification, "facing" means that two surfaces or members are in a position where they face each other, and includes not only cases where they are completely facing each other, but also cases where they are partially facing each other. Furthermore, in this specification, "facing" includes both cases where a member other than the two parts is interposed between the two parts, and cases where nothing is interposed between the two parts.

[0017] <Embodiment 1> Embodiment 1 of this disclosure will be described with reference to Figures 1 to 7. The reactor 1 of this embodiment is used, for example, as a noise filter for a vehicle. As shown in Figure 1, the reactor 1 comprises a core 2 and a coil 3.

[0018] In the following explanation, the direction indicated by arrow Z will be referred to as the Z direction, the direction indicated by arrow X as the X direction, and the direction indicated by arrow Y as the Y direction. The Z, X, and Y directions are orthogonal. Furthermore, the Z direction is defined as the up-and-down direction, the X direction as the front-and-back direction, and the Y direction as the left-and-right direction. In the case of multiple identical components, a reference numeral may be assigned to only some of the components, while the reference numerals for other components may be omitted.

[0019] (Core 2) As shown in Figure 2, core 2 comprises a first core 4 and a second core 5. The first core 4 and the second core 5 extend in the X direction and face each other in parallel. The first core 4 is composed of a first core block 6 made of magnetic material and a first molded portion 7 made of resin material.

[0020] As shown in Figure 3, the first core block 6 comprises a first block 8 and a second block 9. The first block 8 is elongated in the X direction, and the second block 9 is elongated in the Y direction. The first block 8 and the second block 9 as a whole form an L-shape in plan view.

[0021] As shown in Figure 4, the first molded portion 7 covers the first core block 6. The first molded portion 7 has a first mounting portion 10 and a second mounting portion 11 at its front upper end and rear upper end, respectively. The mounting portions 10 and 11 facilitate fastening to other fastening portions. In addition, a first molded portion projection 12 is provided on the inner surface of the first molded portion 7. The first molded portion projection 12 covers the tip portion of the second block 9.

[0022] The second core 5 has the same basic structure as the first core 4 and comprises a second core block 13 made of magnetic material and a second molded part 14 made of resin material.

[0023] As shown in Figure 3, the second core block 13 comprises a third block 15 and a fourth block 16. The third block 15 is elongated in the X direction, and the fourth block 16 is elongated in the Y direction. The third block 15 and the fourth block 16 as a whole form an L-shape in plan view.

[0024] As shown in Figure 4, the second molded portion 14 covers the second core block 13. The front upper end and rear upper end of the second molded portion 14 are provided with a third mounting portion 17 and a fourth mounting portion 18, respectively. The mounting portions 17 and 18 facilitate fastening to other fastening portions. In addition, a second molded portion projection 19 is provided on the inner surface of the second molded portion 14. The second molded portion projection 19 covers the tip portion of the fourth block 16.

[0025] As shown in Figure 3, the first core block 6 and the second core block 13 are ring-shaped as a whole, forming a closed magnetic path U. The first coil 20 is fitted onto the first core 4, and the second coil 21 is fitted onto the second core 5.

[0026] (Coil 3) As shown in Figure 5, the coil 3 comprises a first coil 20 fitted onto the first core 4, a second coil 21 fitted onto the second core 5, and a folded member 22.

[0027] (Coil 1, 20) As shown in Figure 5, the first coil 20 includes a first coil first busbar 23, a first coil second busbar 24, and a first coil third busbar 25, all of which are made of conductive plate material.

[0028] As shown in Figure 6, the first coil first busbar 23 comprises a first coil first busbar bottom wall 26, a first coil first busbar first side wall 27, a first coil first busbar second side wall 28, and a first coil first busbar top wall 29. The first coil first busbar first side wall 27 and the first coil first busbar second side wall 28 are provided on both sides in the Y direction of the first coil first busbar bottom wall 26. The first coil first busbar first side wall 27 extends straight upward from the first coil first busbar bottom wall 26. On the other hand, the first coil first busbar second side wall 28 extends diagonally backward in the X direction from the first coil first busbar bottom wall 26. The first coil first busbar top wall 29 is formed at the upper end of the first coil first busbar second side wall 28. A first coil terminal section 30 is integrally provided on the upper wall 29 of the first coil's first busbar.

[0029] The first coil second busbar 24 comprises a first coil second busbar bottom wall 31, a first side wall 32, a second side wall 33, and a first coil second busbar top wall 34. The first side walls 32 and 33 are provided on both sides in the Y direction of the first coil second busbar bottom wall 31. The first side wall 32 extends straight upward from the first coil second busbar bottom wall 31. On the other hand, the second side wall 33 extends diagonally backward in the X direction from the first coil second busbar bottom wall 31. The first coil second busbar top wall 34 is formed at the upper end of the first coil second busbar second side wall 33. The upper wall 34 of the first coil second busbar has a flange 35 integrally provided on it. The first coil second busbar 24 has the same basic structure as the first coil first busbar 23, except that it does not have a first coil terminal portion 30 and has a flange 35.

[0030] Since the third busbar 25 of the first coil has the same structure as the second busbar 24 of the first coil, the same reference numerals are used for the same structural parts, and the explanation is omitted.

[0031] The first coil's first busbar 23, the first coil's second busbar 24, and the first coil's third busbar 25 each constitute a coil with one turn, with the X direction as its axis. As shown in Figure 5, the upper ends of these three busbars 23, 24, and 25 of the first coil 20 are welded together in a butt position, with the first side wall 27 of the first coil's first busbar and the flange 35 of the first coil's second busbar, and the first side wall 32 of the first coil's second busbar and the flange 35 of the first coil's third busbar, respectively. As a result, the first coil's first busbar 23, the first coil's second busbar 24, and the first coil's third busbar 25 constitute a first coil 20 with three turns, with the X direction as its axis.

[0032] (2nd coil 21) The second coil 21 comprises a second coil terminal portion 36, a second coil first busbar 37, a second coil second busbar 38, and a second coil third busbar 39, all made of conductive plate material. The second coil terminal portion 36 is generally the same shape as the first coil terminal portion 30. The second coil terminal portion 36 has a terminal flange 40 at its front end in the X direction.

[0033] The second coil first busbar 37 comprises a second coil first busbar bottom wall 41, a second side wall 42, a second side wall 43, and a second coil first busbar top wall 44. The second coil first busbar first side wall 42 and the second side wall 43 are provided on both sides in the Y direction of the second coil first busbar bottom wall 41. The second coil first busbar first side wall 42 extends straight upward from the second coil first busbar bottom wall 41. On the other hand, the second coil first busbar second side wall 43 extends diagonally forward in the X direction from the second coil first busbar bottom wall 41. The second coil first busbar top wall 44 is formed at the upper end of the second coil first busbar second side wall 43. The flange 45 of the second coil first busbar is integrally provided on the upper wall 44 of the second coil first busbar.

[0034] Since the second coil second busbar 38 and the second coil third busbar 39 have the same structure as the second coil first busbar 37, the same reference numerals are used for the same structural parts, and their explanation is omitted.

[0035] The second coil's first busbar 37, second coil's second busbar 38, and second coil's third busbar 39 each constitute a coil with one turn, with the X direction as its axis. As shown in Figure 5, the upper ends of these three busbars 37, 38, and 39 of the second coil 21 are welded together with the terminal flange 40 and the first side wall 42 of the second coil's first busbar, the second coil's first busbar flange 45 and the first side wall 42 of the second coil's second busbar, and the second coil's second busbar flange 45 and the first side wall 42 of the second coil's third busbar, respectively, in a butt-joined state. As a result, the second coil's first busbar 37, second coil's second busbar 38, and second coil's third busbar 39 constitute a second coil 21 with three turns, with the X direction as its axis.

[0036] (Folded back member 22) The folded member 22 is a member that connects the two coils 21 and 22 in a folded state. Folding means reversing the winding direction of the coils. In this example, the winding direction of coil 3 is reversed from forward in the X direction (winding direction of the first coil 20) to backward in the X direction (winding direction of the second coil 21). The folded member 22 is made of a conductive plate material and has a first flange 46 and a second flange 47. The first flange 46 corresponds to the first side wall 32 of the third busbar of the first coil, and the second flange 47 corresponds to the flange 45 of the third busbar of the second coil.

[0037] The first flange 46 of the folded member 22 and the first coil 20 (specifically, the first side wall 32 of the third busbar of the first coil), and the second flange 47 of the folded member 22 and the second coil 21 (specifically, the flange 45 of the third busbar of the second coil) are butted together and their upper end faces are welded to each other. As a result, the first coil 20 and the second coil 21 are joined in a folded state, forming a 6-turn coil 3 with the X direction as the axial direction.

[0038] Figure 7 shows the positional relationship between the folded member 22 and the core. As shown in Figure 7, the folded member 22 generally overlaps with the front part of the first block 8 of the core block 6 in a plan view.

[0039] In this way, by keeping the folded member 22 within the outer shape range of the core 2 and positioning it on the core, it is possible to suppress the protrusion of the folded member 22 relative to the outer shape of the core, thereby improving the volumetric efficiency of the coil 3.

[0040] (Effects of the embodiment) (1) The reactor 1 according to Embodiment 1 comprises a core 2 and a coil 3 fitted onto the core 2, and the coil 3 is composed of a plurality of busbars 23-25, 37-39 that are welded together. In other words, the winding portion of the coil 3 is divided into turns by the plurality of busbars 23-25, 37-39. This configuration has the advantage of reducing positional deviation due to winding and making it easier to achieve precision compared to the case in which the coil 3 is composed of a single busbar.

[0041] (2) In the reactor 1 according to Embodiment 1, the coil 3 has an even number of turns, and the folded member 22 is placed on the core 2. This configuration makes it possible to suppress the protrusion of the folded member 22 relative to the outer shape of the core, and improves the volumetric efficiency of the coil 3.

[0042] <Embodiment 2> Figure 8 is a perspective view of coil 51. Coil 51 represents another form of coil 3 disclosed in Embodiment 1, and comprises a first coil 52 fitted onto the first core 4 and a second coil 53 fitted onto the second core 5.

[0043] The first coil 52, like coil 3, includes a first coil first busbar 54, a first coil second busbar 55, and a first coil third busbar 56, while the second coil 53 includes a second coil first busbar 58, a second coil second busbar 59, and a second coil third busbar 60.

[0044] There are two main differences between coil 51 and coil 3. The first difference is the welding method of the busbars. Coil 3 is welded with the parts to be welded butt together, while coil 51 is welded with the parts to be welded overlapping vertically.

[0045] Specifically, as shown in Figure 9, the first coil first busbar 54 has a first coil first busbar flange 62 that bends inward at the upper end of the first side wall 61 of the first coil first busbar. The first coil second busbar 55 has a first coil second busbar upper wall 64 at the upper end of the second side wall 63 of the first coil second busbar. The first coil first busbar flange 62 overlaps the upper surface of the first coil second busbar upper wall 64, and the first coil first busbar flange 62 can be welded to the first coil second busbar upper wall 64. Other parts are welded in the same manner.

[0046] The second difference is that, as shown in Figure 8, the folded member 65 is integrally formed with the second coil third busbar 60. By integrating the folded member 65 with the second coil third busbar 60, the number of parts and welding points can be reduced.

[0047] (Welding jig 70) Figure 10 is a perspective view of the welding jig 70. The welding jig 70 comprises a base 71, a first positioning member 72, a second positioning member 73, an intermediate plate 74, and an upper plate 75.

[0048] The first positioning member 72 is a member that positions the first coil 52 in the X direction, and has a positioning groove 76 on its upper surface.

[0049] The second positioning member 73 is a member that positions the second coil 53 in the X direction and has a positioning groove 77 on its upper surface. These positioning grooves 76 and 77 are installed for each busbar, allowing for positioning on a busbar-by-busbar basis.

[0050] The intermediate plate 74 is located between the first coil 52 and the second coil 53, and its role is to maintain the distance between the two coils 52 and 53 so that they do not come into contact and short-circuit.

[0051] The top plate 75 is sized to cover the entirety of the first coil 52 and the second coil 53, and is fixed to the upper surfaces of the first positioning member 72 and the second positioning member 73 with bolts. The top plate 75 has welding openings 78 and 79 formed therein, and the busbars 54-56 and 58-60 are laser welded through these openings 78 and 79.

[0052] By using the welding jig 70, the displacement of each bus bar 54-56 and 58-60 during welding can be suppressed. In addition, it is possible to suppress the adhesion of welding spatter to each bus bar 54-56 and 58-60. The same welding jig 70 can also be applied to the coil 3 disclosed in Embodiment 1 during welding to suppress the displacement of each bus bar 23-25 ​​and 37-39 during welding.

[0053] <Embodiment 3> Figure 11 is a perspective view of reactor 81. Reactor 81 comprises a core 2 and a coil 82. Core 2 is the same as core 2 of reactor 1 in embodiment 1 and comprises a first core 4 and a second core 5.

[0054] The coil 82 comprises a first coil 83 fitted onto the first core 4 and a second coil 84 fitted onto the second core 5.

[0055] (Coil 1, 83) As shown in Figure 12, the first coil 83 includes a first coil first busbar 85, a first coil second busbar 86, and a first coil third busbar 87, all of which are made of conductive plate material.

[0056] The first coil first busbar 85, the first coil second busbar 86, and the first coil third busbar 87 have the same structure as the first coil first busbar 23, the first coil second busbar 24, and the first coil third busbar 25 of Embodiment 1. Therefore, the same structural parts are denoted by the same reference numerals, and their descriptions are omitted.

[0057] As shown in Figures 12 and 13, the three busbars 85, 86, and 87 are welded together with the first side wall 27 of the first coil first busbar and the flange 35 of the first coil second busbar, and the first side wall 32 of the first coil second busbar and the flange 35 of the first coil third busbar, respectively, in a butt-joined state. As a result, the first coil first busbar 85, the first coil second busbar 86, and the first coil third busbar 87 constitute a three-turn first coil 83 with the X direction as its axis.

[0058] (Second coil 84) The second coil 84 comprises a second coil terminal portion 88, a second coil first busbar 89, and a second coil second busbar 90, all made of conductive plate material. The second coil terminal portion 88 has the same shape as the second coil terminal portion 36 of Embodiment 1, and the second coil first busbar 89 and second coil second busbar 90 have the same shapes as the second coil first busbar 37 and second coil second busbar 38 of Embodiment 1. Therefore, the same structural parts are denoted by the same reference numerals, and their descriptions are omitted.

[0059] As shown in Figures 12 and 13, the second coil first busbar 89 and the second coil second busbar 90 are welded together with the terminal flange 40 of the second coil terminal 88 and the first side wall 42 of the second coil first busbar, and the flange 45 of the second coil first busbar and the first side wall 42 of the second coil second busbar, respectively, forming a two-turn second coil 84 with its axis in the X direction.

[0060] Then, by welding the flange 45 of the second busbar 90 of the second coil to the first side wall 32 of the third busbar of the first coil while abutting them together, the first coil 83 and the second coil 84 are joined together to form a 5-turn coil 82.

[0061] As shown in Figure 14, the reactor 81 of Embodiment 3 has folded portions 92 of the first coil 83 and the second coil 84 in the gap 91 between the first core 4 and the second core 5. The folded portion 92 is the part where the two coils 83 and 84 are joined in a folded state, and in this example, it is the joint portion between the first side wall 32 of the third busbar of the first coil and the second busbar flange 45 of the second coil.

[0062] By using the gap 91 between the cores to fold the coil 82, the folded portion does not protrude from the outer shape of the core, improving the volumetric efficiency of the coil 82.

[0063] (Other embodiments) The above embodiment can be implemented with the following modifications. The above embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0064] In embodiments 1 and 2, reactors 1 and 81 were used as noise filters, but reactors 1 and 81 may be used for other purposes.

[0065] In Embodiment 1, the number of turns of coil 3 was set to 6. The number of turns of coil 3 may be an even number other than 6, such as 4 or 8. Also, in Embodiment 2, the number of turns of coil 82 was set to 5, but the number of turns of coil 82 may be an odd number other than 5, such as 3 or 7.

[0066] In embodiments 1 and 2, the busbars were laser-welded together, but welding may be performed using methods other than lasers.

[0067] In Embodiment 1, the winding portion of coil 3 was divided into one-turn sections by six busbars 23-25 ​​and 37-39. The method of dividing coil 3 is not limited to the example of this embodiment; for example, it may be divided into sections of one turn or less, or into sections of several turns. Any configuration is acceptable as long as the winding portion of coil 3 is divided by multiple busbars. The same applies to coil 82. [Explanation of symbols]

[0068] 1: Reactor 2: Core 3: Coil 4: First Core 5: Second Core 6: First Core Block 7: First mold section 8: Block 1 9: Block 2 10: First mounting section 11: Second mounting section 12: First mold projection 13: Second Core Block 14: Second mold section 15: Block 3 16: Block 4 17: Third mounting section 18: Fourth mounting section 19: Protruding part of the second mold 20: First coil 21: Second coil 22: Folding member 23: First coil, first busbar 24: First coil, second busbar 25: First coil, third busbar 26: First coil, first busbar bottom wall 27: First coil, first busbar, first side wall 28: First coil, first busbar, second side wall 29: Upper wall of the first coil and first busbar 30: First coil terminal section 31: First coil, second busbar bottom wall 32: First coil, second busbar, first side wall 33: First coil, second busbar, second side wall 34: Upper wall of the second busbar of the first coil 35: First coil, second busbar flange 36: Second coil terminal section 37: Second coil, first busbar 38: Second coil, second busbar 39: Second coil, third busbar 40: Terminal flange 41: Second coil, first busbar bottom wall 42: Second coil, first busbar, first side wall 43: Second coil, first busbar, second side wall 44: Upper wall of the first busbar of the second coil 45: Second coil, first busbar flange 46: First flange 47: Second flange 51: Coil 52: First Coil 53: Second coil 54: First coil, first busbar 55: First coil, second busbar 56: First coil, third busbar 58: Second coil, first busbar 59: Second coil, second busbar 60: Second coil, third busbar 61: First coil, first busbar, first side wall 62: First coil, first busbar flange 63: First coil, second busbar, second side wall 64: Upper wall of the second busbar of the first coil 65: Folding member 70: Welding jigs 71: Bass 72: First positioning member 73: Second positioning member 74: Intermediate plate 75: Top plate 76, 77: Positioning grooves 78, 79: Opening 81: Reactor 82: Coil 83: First coil 84: Second coil 85: First coil, first busbar 86: First coil, second busbar 87: First coil, third busbar 88: Second coil terminal section 89: Second coil, first busbar 90: Second coil, second busbar 91: Gap 92: Folded section

Claims

1. It is a reactor, The core and The system comprises a coil fitted onto the core, The coil is a reactor composed of multiple busbars welded together.

2. The aforementioned core comprises a first core and a second core facing each other in parallel, The coil comprises a first coil fitted onto the first core and a second coil fitted onto the second core. If the coil has an even number of turns, The reactor according to claim 1, wherein the folded members of the first coil and the second coil are arranged on the core.

3. The aforementioned core comprises a first core and a second core facing each other in parallel, The coil comprises a first coil fitted onto the first core and a second coil fitted onto the second core. If the coil has an odd number of turns, The reactor according to claim 1, wherein the folded portions of the first coil and the second coil are placed in the gap between the first core and the second core.

4. The reactor according to claim 1, wherein the core comprises a molded portion made of a resin material.

5. The reactor according to claim 4, wherein the molded portion includes a mounting portion.

Images