Reactor structure, converter, and power conversion device

Abstract

To provide a reactor structure, a converter, and an electric conversion device, with high productivity.SOLUTION: A reactor structure α comprises: a reactor 1 having a coil and a core; and a bus bar 4 electrically connecting the coil with external equipment. The reactor 1 comprises a pin 5 that determines a position of the bus bar against the reactor. The bus bar 4 comprises: a first piece 41 connected to a winding end part 21 of the coil in an overlapping state; a second piece 42 connected to external equipment; and a main body piece 40 connecting the first piece and the second piece. The main body piece comprises a long hole shape slide hole 4h extended to a X direction. The X direction is a direction where the winding end part 21 and the first piece 41 are arranged in parallel. The pin 5 penetrates the slide hole 4h to regulate a motion of the bus bar in a direction intersecting a projection direction of the X direction and the pin 5.SELECTED DRAWING: Figure 1

Description

[Technical field]

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

[0002] A reactor structure is an example of a component of a converter installed in a hybrid vehicle or the like. For example, the reactor structure disclosed in Patent Document 1 includes a reactor and a terminal member. The reactor includes a coil and a core. The coil is formed by winding a wire in a spiral shape. The reactor described in Patent Document 1 further includes a frame-shaped bobbin, an inner bobbin, and a case. The frame-shaped bobbin and the inner bobbin are insulating members that ensure insulation between the coil and the core. The case houses the assembly of the coil, the core, and the insulating member.

[0003] The terminal member provided in the reactor structure is also called a bus bar. The bus bar electrically connects the coil and an external device. The end of the bus bar is connected to the end of the coil by welding or the like. The middle part of the bus bar described in Patent Document 1 is screwed to a case that constitutes the reactor. By screwing the bus bar to the case, the position of the bus bar relative to the reactor is determined, making it easy to connect the end of the bus bar to the end of the coil. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP2014-130949A Summary of the Invention [Problem to be solved by the invention]

[0005] In the reactor structure of Patent Document 1, it is time-consuming to screw the bus bars. Also, the number of parts constituting the reactor structure increases. Therefore, the productivity of the reactor structure of Patent Document 1 is poor.

[0006] In view of the above, an object of the present disclosure is to provide a reactor structure with excellent productivity, and a converter and a power conversion device with excellent productivity. [Means for solving the problem]

[0007] The reactor structure of the present disclosure includes: a reactor having a coil and a core; A reactor structure including a bus bar electrically connecting the coil and an external device, The reactor is a pin for determining a position of the bus bar relative to the reactor, The bus bar includes: A first piece connected to an end of a winding of the coil in an overlapping state; A second piece connected to the external device; a main body piece connecting the first piece and the second piece, The main body piece has a long slide hole extending in the X direction, the X direction is a direction in which the winding end portion and the first piece are arranged side by side, The pin passes through the slide hole and restricts movement of the bus bar in a direction intersecting the X direction and a protruding direction of the pin.

[0008] The converter of the present disclosure comprises: The reactor structure according to the present disclosure is provided.

[0009] The power conversion device of the present disclosure includes: Equipped with a converter according to the present disclosure. Effect of the Invention

[0010] The reactor structure, the converter, and the power conversion device of the present disclosure are excellent in productivity. [Brief description of the drawings]

[0011] [Figure 1]FIG. 1 is a schematic perspective view of a reactor structure according to a first embodiment. [Diagram 2] FIG. 2 is a schematic perspective view of an assembly provided in the reactor structure according to the first embodiment. [Diagram 3] FIG. 3 is a schematic perspective view of a bus bar provided in the reactor structure according to the first embodiment. [Figure 4] FIG. 4 is a schematic top view of a bus bar provided in the reactor structure according to the first embodiment. [Diagram 5] FIG. 5 is a schematic perspective view of a base portion provided in the reactor structure according to the first embodiment. [Figure 6] FIG. 6 is an explanatory diagram showing a manufacturing procedure of the reactor structure according to the first embodiment. [Figure 7] FIG. 7 is an explanatory diagram showing the positional relationship between the pins and the bus bars during manufacture of the reactor structure according to the first embodiment. [Figure 8] FIG. 8 is a schematic perspective view of a bus bar provided in the reactor structure according to the second embodiment. [Figure 9] FIG. 9 is a schematic front view of a reactor provided in the reactor structure according to the third embodiment. [Figure 10] FIG. 10 is a schematic diagram showing a power supply system of a hybrid vehicle according to the fourth embodiment. [Figure 11] FIG. 11 is a circuit diagram illustrating an example of a power conversion device including a converter according to the fourth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] [Description of the embodiments of the present disclosure] First, the embodiments of the present disclosure will be listed and described.

[0013] <1> The reactor structure according to the embodiment includes: a reactor having a coil and a core; A reactor structure including a bus bar electrically connecting the coil and an external device, The reactor is a pin for determining a position of the bus bar relative to the reactor, The bus bar includes: A first piece connected to an end of a winding of the coil in an overlapping state; A second piece connected to the external device; a main body piece connecting the first piece and the second piece, The main body piece has a long slide hole extending in the X direction, the X direction is a direction in which the winding end portion and the first piece are arranged side by side, The pin passes through the slide hole and restricts movement of the bus bar in a direction intersecting the X direction and a protruding direction of the pin.

[0014] The reactor structure has excellent productivity. When the reactor structure is fabricated, the slide hole of the bus bar is fitted onto the pin, and the bus bar is simply slid in the X direction, so that the first piece of the bus bar abuts against the winding end. The movement of the bus bar after sliding is restricted by the pin, so the bus bar is held relative to the reactor. Therefore, in the reactor structure of this example, the first piece of the bus bar and the winding end can be easily connected even without screws for fixing the bus bar to the reactor. In this way, the reactor structure does not require screws for fixing the bus bar, and does not require the work of attaching the screws. Therefore, the reactor structure has excellent productivity.

[0015] <2> As one embodiment of the reactor structure according to the present invention, The slide hole includes a large hole portion and a small hole portion that are connected in the X direction, the large hole portion is disposed on the first piece side relative to the small hole portion in the X direction, In one embodiment, the pin is disposed in the small hole when the winding end and the first piece are connected to each other.

[0016] The slide hole has a large hole portion, so that the pin can be easily fitted into the slide hole of the bus bar. When the bus bar is slid in the X direction, the pin is disposed in the small hole portion. The small hole portion restricts the movement of the bus bar in the width direction of the small hole portion. The width direction of the small hole portion is a direction intersecting the X direction and the protruding direction of the pin. By restricting the movement of the bus bar in the width direction of the small hole portion, vibration of the bus bar relative to the reactor is suppressed when the reactor vibrates during operation of the reactor. As a result, stress caused by vibration of the bus bar is less likely to act on the connection point between the first piece and the winding end portion.

[0017] <3> The above form <2> As one embodiment of the reactor structure according to the present invention, The pin is A shaft portion, A head provided at a tip of the shaft portion, The shaft portion passes through the small hole portion, The head is disposed outside the small hole, An outer dimension of the head as viewed in the axial direction of the shaft portion may be greater than a width of the small hole.

[0018] As described above, the width of the small hole is in a direction intersecting the X direction and the protruding direction of the pin. If the outer dimension of the pin head is larger than the width of the small hole, the bus bar will get caught on the pin head when it vibrates in the protruding direction of the pin. <3> In the configuration, the shaft of the pin restricts the movement of the bus bar in the width direction of the small hole, and the head of the pin restricts the movement of the bus bar in the protruding direction of the pin. <3> In the above configuration, <2> In this configuration, stress caused by vibration of the bus bar is less likely to act on the connection portion between the first piece and the winding end.

[0019] <4> The above form <3> As a reactor structure relating to the above, the head has a shape in which the first piece side in the X direction is notched, The large hole may have a shape that conforms to the shape of the head.

[0020] The head is made smaller by missing a part of it. The inner peripheral shape of the large hole portion is shaped to follow the outline of the head as seen from the axial direction of the pin. Therefore, when the head is made smaller, the area occupied by the large hole portion is also reduced. As a result, the reduction in strength of the busbar caused by the large hole portion is suppressed.

[0021] <5> As one embodiment of the reactor structure according to the present invention, the reactor includes a through hole through which a screw for fixing the reactor to an installation target is inserted, The axis of the through hole coincides with the Y direction or the Z direction, the Y direction intersects with the X direction and is aligned along the extension direction of the winding end portion, The Z direction may be a direction intersecting the X direction and the Y direction.

[0022] In general, a reactor fixed to an installation object is likely to vibrate in a direction along the axis of the through hole during use. Since the bus bar is configured to be slidable in the X direction when attached, if the axis of the through hole coincides with the X direction, a strong stress is likely to act on the connection between the first piece of the bus bar and the winding end. <5> In this configuration, the axis of the through hole is disposed so as to intersect with the X-direction, so that strong stress is unlikely to act on the connection portion.

[0023] <6> The above form <5> As the reactor structure, The axis of the through hole coincides with the Z direction, The pin may be configured to protrude in the Y direction.

[0024] The above form <6> In the above configuration, the reactor is prone to vibrating in the Z direction, which coincides with the axis of the screw shaft. In this configuration, if the pin protrudes in the Y direction, which intersects with the Z direction, the movement of the busbar in the Z direction is restricted by the inner periphery of the slide hole being abutted against the shaft of the pin. <6> In this configuration, vibration of the bus bar in the Z direction is effectively suppressed.

[0025] <7> The above form <5> Or form <6> As the reactor structure, The axis of the through hole coincides with the Z direction, The bus bar has a first plane parallel to an XY plane, The reactor includes a base portion protruding in the Z direction, The base portion may include a support portion that supports the first plane in parallel to the XY plane.

[0026] When the bus bar is attached to the reactor, the reactor is placed on a horizontal work table, and the bus bar is attached to the reactor. In a configuration in which the axis of the through hole coincides with the Z direction, the reactor is placed on the work table so that the XY plane is parallel to the work table. If the reactor has a support portion that supports the bus bar parallel to the XY plane, the bus bar is unlikely to rotate around its axis when it is slid. Therefore, when the bus bar is slid and the first piece of the bus bar abuts against the winding end, the first piece is unlikely to shift from the winding end.

[0027] The above form <7> In the configuration, the bus bar is stably held on the support part parallel to the XY plane, so when the reactor vibrates in the Z direction, the bus bar easily moves in the Z direction together with the reactor. Therefore, the movement of the reactor and the movement of the bus bar are unlikely to be out of sync, and vibration of the bus bar relative to the reactor is easily suppressed.

[0028] <8> As one embodiment of the reactor structure according to the present invention, The reactor includes an insulating member that determines a relative position between the coil and the core, The pin may be provided integrally with the insulating member.

[0029] Since the bus bar is a conductive member, it is necessary to ensure insulation between the bus bar and the coil, and insulation between the bus bar and the core. <8> In the case of the coil-core type, the pin is formed of a part of an insulating material, so that the insulation is ensured. Here, an example of the insulating material that determines the relative positions of the coil and the core is a holding member that is disposed between the end of the coil and the core. Another example of the insulating material is a resin molded part that integrates the coil and the core.

[0030] <9> The above form <8> As the reactor structure, The insulating member may be a resin molded part that integrates the coil and the core.

[0031] The resin molded portion makes it difficult for the coil and the core to come apart, which makes the assembly of the coil and the core easier to handle.

[0032] <10> As one embodiment of the reactor structure according to the present invention, The reactor includes a case that houses an assembly of the core and the coil, the case includes a resin portion made of an insulating material, The pin may be provided integrally with the resin portion.

[0033] The pin is made of a part of the resin part of the case, so that insulation between the bus bar and the core is ensured. The entire case may be made of an insulating material, or only a part of the case may be made of an insulating material.

[0034] <11> The converter according to the embodiment includes: The above form <1> From form <10> The reactor structure is any one of the above.

[0035] The converter includes the reactor structure according to the embodiment, which is excellent in productivity. Therefore, the converter has excellent productivity.

[0036] <12> The power conversion device according to the embodiment includes: the above <11> Equipped with a converter.

[0037] The power conversion device includes the converter according to the embodiment, which is excellent in productivity. Therefore, the power conversion device has excellent productivity.

[0038] [Details of the embodiment of the present disclosure] Hereinafter, embodiments of a reactor structure, a converter, and a power conversion device according to the present disclosure will be described with reference to the drawings. The same reference numerals in the drawings indicate the same objects. Note that the present invention is not limited to the configurations shown in the embodiments, but is indicated by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0039] <Embodiment 1> In the first embodiment, the configuration of the reactor structure α will be described with reference to Fig. 1 to Fig. 7. The reactor structure α shown in Fig. 1 includes a reactor 1 having a coil 2 and a core 3 (Fig. 2), and a bus bar 4 that electrically connects the coil 2 to an external device. One of the features of this reactor structure α is the configuration of the bus bar 4. Each component of the reactor structure α will be described in detail below.

[0040] <Reactor> The reactor 1 of this example includes an assembly 10 (FIG. 2) and an insulating member 9. As shown in FIG. 2, the assembly 10 is a combination of a coil 2 and a core 3. The insulating member 9 determines the relative positions of the coil 2 and the core 3.

[0041] [coil] The coil 2 of this example has a winding portion 20 formed by winding a wire. A known winding can be used for the winding. The winding of this example is a coated rectangular wire. The conductor wire of the coated rectangular wire is made of a rectangular copper wire. The insulating coating of the coated rectangular wire is made of enamel. The winding portion 20 is made of an edgewise coil in which the coated rectangular wire is wound edgewise. The coil 2 used in this example has one winding portion 20. Unlike this example, the coil 2 may have multiple winding portions 20. For example, a coil 2 having two winding portions 20 arranged in parallel with each other can be used.

[0042] The shape of the winding part 20 is a rectangular tube. The rectangle includes a square. That is, the end face shape of the winding part 20 is a rectangular frame shape. Since the shape of the winding part 20 is a rectangular tube, the contact area between the winding part 20 and the installation object is likely to be larger than when the winding part is a cylinder of the same cross-sectional area. As a result, the heat of the reactor structure α is likely to be dissipated to the installation object via the winding part 20. Furthermore, the stability of the winding part 20 with respect to the installation object is improved. It is preferable that the corners of the winding part 20 are rounded.

[0043] The winding ends 21, 22 of the coil 2 are each extended toward the outer periphery of the winding portion 20. The insulating coating is stripped away from the winding end 21 and the winding end 22 to expose the conductor wire. A bus bar 4 is connected to the exposed conductor wire. In the figure of this example, only the bus bar 4 attached to the winding end 21 is shown. The configuration of the bus bar attached to the winding end 22 may be the same as that of the bus bar 4 shown in the figure, or may be different. An external device is connected to the coil 2 via the bus bar 4. The external device is not shown in the figure. An example of the external device is a power source that supplies power to the coil 2.

[0044] Here, the directions in the reactor structure α are defined based on the coil 2 and the busbar 4. First, the direction in which the winding end 21 of the coil 2 and the first piece 41 of the busbar 4 are arranged in parallel is defined as the X direction. The first piece 41 is a portion of the busbar 4 that is connected in a state of being overlapped with the winding end 21. A detailed configuration of the first piece 41 will be described later. The direction that intersects with the X direction and follows the extension direction of the winding end 21 is defined as the Y direction. In this example, the Y direction is perpendicular to the X direction. And the direction that intersects with both the X direction and the Y direction is defined as the Z direction. In this example, the Z direction is perpendicular to the X direction and the Y direction. Furthermore, the following directions are defined. X1 direction: the X direction toward the winding end 21 as viewed from the bus bar 4 X2 direction: opposite direction to X1 direction Y1 direction: the Y direction toward the tip of the winding end 21 -Y2 direction: opposite direction to Y1 direction Z1 direction: The Z direction away from the object on which Reactor 1 is installed (upward on the page) Z2 direction: opposite direction to Z1 direction

[0045] [core] The core 3 is a magnetic body in which a closed magnetic circuit is formed. The core 3 is composed of a powder compact, a composite material compact, etc. The powder compact is formed by pressing raw powder containing soft magnetic powder. Examples of soft magnetic powder include pure iron and iron alloys. The composite material compact is formed by filling a mold with a mixture of soft magnetic powder and unsolidified resin and solidifying the resin. In the composite material compact, the soft magnetic powder is dispersed in the resin.

[0046] The core 3 includes an inner core portion 31 and an outer core portion 32. The inner core portion 31 is disposed inside the winding portion 20 of the coil 2, and is a portion along the axial direction of the winding portion 20. In this example, both ends of the portion of the core 3 along the axial direction of the winding portion 20 protrude from the end faces of the winding portion 20. The protruding portions are also part of the inner core portion 31.

[0047] The shape of the inner core portion 31 is not particularly limited as long as it fits the internal shape of the winding portion 20. The inner core portion 31 in this example is substantially rectangular parallelepiped. The inner core portion 31 may be configured by connecting a plurality of split cores and a gap plate, or may be formed as a single member.

[0048] The outer core portion 32 is a portion of the core 3 that is disposed outside the winding portion 20. The shape of the outer core portion 32 is not particularly limited as long as it connects the ends of the inner core portion 31. The outer core portion 32 of this example includes an end core piece facing an end face of the winding portion 20 in the Y1 direction, an end core piece facing an end face of the winding portion 20 in the Y2 direction, a side core piece facing a side face of the winding portion 20 in the X1 direction, and a side core piece facing a side face of the winding portion 20 in the X2 direction. Therefore, the outer core portion 32 of this example is rectangular and annular when viewed from the Z direction.

[0049] The core 3 in this example is composed of two split cores 3A and 3B. The split core 3A is substantially T-shaped when viewed from the Z direction. The split core 3B is substantially E-shaped when viewed from the Z direction. The shapes of the split cores 3A and 3B are not particularly limited. For example, a combination of a substantially I-shaped split core that becomes the inner core portion 31 and a substantially O-shaped split core that becomes the outer core portion 32 can be used. The core 3 may be composed of three or more split cores. For example, a combination of a substantially I-shaped split core that becomes the inner core portion 31 and two substantially U-shaped split cores that become the outer core portion 32 can be used.

[0050] [Insulating material] The insulating member 9 in this example is a resin molded part 6 that integrates the coil 2 and the core 3. The resin molded part 6 also has a function of protecting the coil 2 and the core 3 from the external environment. The resin molded part 6 in this example does not cover the outer surface in the Z direction of the winding part 20. In other words, the outer surface in the Z direction of the winding part 20 is exposed from the resin molded part 6. As a result, heat generated in the coil 2 is easily released to the outside.

[0051] The resin molded part 6 is made of a thermoplastic resin such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin, polybutylene terephthalate (PBT) resin, or acrylonitrile butadiene styrene (ABS) resin. Alternatively, the resin molded part 6 may be made of a thermosetting resin such as unsaturated polyester resin, epoxy resin, urethane resin, or silicone resin. By including a ceramic filler in these resins, the heat dissipation properties of the resin molded part 6 are improved. Examples of the ceramic filler include non-magnetic powders such as alumina and silica.

[0052] The resin molded portion 6 includes a terminal block 61. The terminal block 61 is a base for supporting a connection terminal of an external device (not shown). The connection terminal is placed on a surface of the bus bar 4 facing the Z1 direction and screwed in. The terminal block 61 is provided with a screw hole 61h into which a screw for fixing the connection terminal is attached. In this example, the screw hole 61h extends in the Z direction. In this example, a nut is embedded in the terminal block 61. The inner peripheral surface of the nut constitutes the screw hole 61h. The axis of the screw hole 61h coincides with the axis of a terminal hole 42h of the bus bar 4 described later. Therefore, by screwing in the connection terminal, the connection terminal is fixed to the terminal block 61 and is electrically connected to the bus bar 4. Here, the nut is not essential. The axis of the screw hole 61h may extend in a direction intersecting the Z direction.

[0053] The resin molded part 6 does not have to cover the entire assembly 10. For example, the resin molded part 6 may be configured to cover only a lower portion of the assembly 10. The lower surface of the resin molded part 6 is preferably in surface contact with an object (not shown) on which the reactor 1 is to be installed. The resin molded part 6 is preferably provided with an attachment part (not shown). The attachment part is preferably provided with a through hole through which a screw for fixing the reactor 1 to the object is inserted. In this case, the axis of the through hole is preferably aligned with the Z direction.

[0054] As shown in FIG. 5, the resin molded part 6 includes a base part 60 having a pin 5. The base part 60 is provided at a corner between a first surface 6a facing the Z1 direction and a second surface 6b facing the Y1 direction. In other words, the base part 60 is provided from the first surface 6a to the second surface 6b. A support part 8 is provided on a portion of the base part 60 that protrudes from the first surface 6a in the Z1 direction. A pin 5 is provided on a portion of the base part 60 that protrudes from the second surface 6b in the Y1 direction. The base part 60 and the pin 5 are provided integrally with the resin molded part 6.

[0055] The support portion 8 has a plane 8p that supports the bus bar 4, which will be described later, parallel to the XY plane. The plane 8p is parallel to the XY plane. The number of support portions 8 may be one or more. In this example, the number of support portions 8 is two. If there are multiple support portions 8, the bus bar 4 is more likely to be stably supported by the support portions 8.

[0056] The pin 5 is a member that determines the position of the bus bar 4 with respect to the reactor 1. The mechanism by which the position of the bus bar 4 is determined by the pin 5 will be explained when explaining the bus bar 4.

[0057] The pin 5 in this example has a shaft portion 50 and a head 51. The shaft portion 50 is a columnar body. The shaft portion 50 in this example is a cylinder. The head 51 is provided at the tip of the shaft portion 50. The outer dimension of the head 51 as viewed in the axial direction of the shaft portion 50 is larger than that of the shaft portion 50. The outer dimension of the head 51 is larger than the width of the small hole portion h2 (see Figures 4 and 7) of the busbar 4 described below and slightly smaller than the dimension of the large hole portion h1 (see Figures 4 and 7). When viewed from the Y direction, the head 51 has a shape of a circle with a portion in the X1 direction missing (see Figure 7 in particular).

[0058] [others] The reactor 1 may include a holding member (not shown) that holds the coil 2 and the core 3 shown in FIG. 2. The holding member is interposed between the end face of the winding portion 20 and the outer core portion 32, and has the function of ensuring insulation between the coil 2 and the core 3. The holding member is made of an insulating material that can be used in manufacturing the resin molded portion 6. In other words, the holding member is an insulating member 9 that determines the relative positions of the coil 2 and the core 3. When the reactor 1 includes the holding member, the resin molded portion 6 may not be required. In that case, it is preferable that the pin 5 is provided on the holding member.

[0059] Bus bar As shown in Fig. 1, the busbar 4 is a member that electrically connects the coil 2 to an external device (not shown). Therefore, the busbar 4 is made of a metal with excellent electrical conductivity. Examples of such metal include copper, a copper alloy, aluminum, and an aluminum alloy. As shown in Figs. 3 and 4, the busbar 4 includes a first piece 41, a second piece 42, and a main body piece 40.

[0060] The first piece 41 is a portion that is connected to the winding end 21 of the coil 2 in a state where it is overlapped therewith. In this example, the first piece 41 is a rectangular plate. The thickness direction of the rectangular plate-shaped first piece 41 coincides with the X direction. The thickness direction of the winding end 21 made of a rectangular wire also coincides with the X direction. Therefore, the surface of the first piece 41 facing the X1 direction and the surface of the winding end 21 facing the X2 direction are in surface contact. The first piece 41 and the winding end 21 are connected by welding or pressure welding. Examples of welding include TIG welding. Examples of pressure welding include friction stir welding. Alternatively, the first piece 41 and the winding end 21 may be connected by a ring-shaped fastener that fastens the first piece 41 and the winding end 21 from the outer periphery.

[0061] The second piece 42 is a portion that is connected to an external device. The second piece 42 is disposed at a position away from the first piece 41 in the X2 direction. In FIG. 3, the boundary between the second piece 42 and the main body piece 40 is indicated by a two-dot chain line. The second piece 42 in this example is formed in a flat plate shape that is connected to a connection terminal of an external device. The thickness direction of the second piece 42 coincides with the Z direction. The second piece 42 is provided with a terminal hole 42h that penetrates the second piece 42 in the thickness direction. The axis of the terminal hole 42h coincides with the Z direction. The terminal hole 42h coincides with the screw hole 61h of the terminal block 61 of the resin molded part 6. The second piece 42 and the connection terminal are electrically connected by overlapping and screwing the connection terminal of the external device on the surface of the second piece 42 facing the Z1 direction.

[0062] The main body piece 40 is a portion that connects the first piece 41 and the second piece 42. In this example, the main body piece 40 is a plate-shaped piece extending in the X direction. The middle portion of the main body piece 40 in the X direction is bent. This bent portion is for making the second piece 42 coincident with the height of the terminal block 61. A protruding portion 40P is provided in the portion of the main body piece 40 on the X2 direction side of the middle portion. The thickness direction of the portion of the main body piece 40 other than the protruding portion 40P coincides with the Z direction. Therefore, the main body piece 40 and the first piece 41 are connected at approximately a right angle.

[0063] As shown in FIG. 4, among the surfaces of the main body piece 40 facing in the Z2 direction, a portion connected to the protruding portion 40P forms a flat first plane 4p. The first plane 4p is located at a position corresponding to the plane 8p of the support portion 8 in the resin molded portion 6 (FIG. 5). The first plane 4p is supported by the plane 8p. Since the plane 8p is parallel to the XY plane, the first plane 4p supported by the plane 8p is also parallel to the XY plane. Therefore, the busbar 4 is stably held on the support portion 8. In the configuration of this example in which the busbar 4 and the resin molded portion 6 are in planar contact, when the reactor 1 vibrates in the Z direction, the busbar 4 easily moves in the Z direction together with the reactor 1. Therefore, the movement of the reactor 1 and the movement of the busbar 4 are unlikely to deviate from each other, and the vibration of the busbar 4 relative to the reactor 1 is easily suppressed.

[0064] The protruding portion 40P of the main body piece 40 is provided at a position closer to the second piece 42 of the main body piece 40. The protruding portion 40P is flat. The thickness direction of the protruding portion 40P coincides with the Y direction. By providing the protruding portion 40P on the main body piece 40, the main body piece 40 gets caught on the corner between the first surface 6a and the second surface 6b of the resin molded portion 6, making it difficult for the bus bar 4 to rotate around the X axis.

[0065] A slide hole 4h is provided in the overhanging portion 40P of the main body piece 40. The slide hole 4h is used when attaching the bus bar 4 to the reactor 1. A specific procedure for attaching the bus bar 4 will be described in the section "Procedure for Attaching the Bus Bar" with reference to FIGS.

[0066] The slide hole 4h is a long hole extending in the X direction. The axial direction of the slide hole 4h coincides with the Y direction. In this example, the slide hole 4h has a large hole portion h1 and a small hole portion h2. The large hole portion h1 and the small hole portion h2 are connected in the X direction. The large hole portion h1 is disposed on the X1 direction side of the small hole portion h2. In other words, the large hole portion h1 is disposed on the first piece 41 side of the small hole portion h2.

[0067] The large hole portion h1 is used when attaching the busbar 4 to the reactor 1 (see the upper diagram in FIG. 7). The large hole portion h1 has a shape that follows the shape of the head 51 of the pin 5 when viewed from the Y direction. More specifically, the portion of the large hole portion h1 on the X1 direction side is straight along the Z direction. The inner dimension of the large hole portion h1 is slightly larger than the outer dimension of the head 51. Therefore, the head 51 is inserted through the large hole portion h1.

[0068] The small hole portion h2 is used to place the busbar 4 at a predetermined position in the reactor 1 (see the lower diagram in FIG. 7). The small hole portion h2 has a shape that follows the shape of the shaft portion 50 of the pin 5 when viewed from the Y direction. In the reactor structure α (FIG. 1), the shaft portion 50 is placed in the small hole portion h2. The width of the small hole portion h2, i.e., the length of the small hole portion h2 in the Z direction, is slightly larger than that of the shaft portion 50. Therefore, when the busbar 4 vibrates in the Z direction, the inner circumferential surface of the small hole portion h2 is caught by the shaft portion 50. Since the movement of the busbar 4 in the Z direction is restricted by the shaft portion 50, the vibration of the busbar 4 in the Z direction relative to the reactor 1 is suppressed. Therefore, stress caused by the vibration of the busbar 4 is less likely to act on the connection portion between the first piece 41 and the winding end portion 21.

[0069] The width of small hole h2, i.e., the length of small hole h2 in the Z direction, is smaller than the outer dimension of head 51. Therefore, when busbar 4 vibrates in the Y direction, the flat surface of protrusion 40P facing the Y1 direction is caught by head 51. Since head 51 restricts the movement of busbar 4 in the Y direction, vibration of busbar 4 in the Y direction relative to reactor 1 is suppressed. Therefore, stress caused by vibration of busbar 4 is less likely to act on the connection point between first piece 41 and winding end 21.

[0070] [Busbar installation procedure] The procedure for attaching the busbar 4 will be described with reference to Figures 6 and 7. First, as shown in Figure 6, the busbar 4 is attached to the pin 5 of the reactor 1. At this time, as shown in the upper diagram of Figure 7, the head 51 of the pin 5 is inserted into the large hole portion h1 of the slide hole 4h. At this point, as shown in Figure 6, the first piece 41 of the busbar 4 is located away from the winding end portion 21. In addition, the terminal hole 42h of the busbar 4 is also located offset from the screw hole 61h of the terminal block 61.

[0071] Next, the busbar 4 is slid in the X1 direction. As a result, as shown in the lower diagram of FIG. 7, the shaft portion 50 of the pin 5 is disposed in the small hole portion h2. At that time, the first plane 4p of the busbar 4 is guided by the plane 8p of the support portion 8. Therefore, the busbar 4 is slid stably without rotating around the X axis. The terminal hole 42h of the slid busbar 4 coincides with the screw hole 61h of the terminal block 61. Also, as shown in FIG. 1, the first piece 41 is abutted against the winding end portion 21. The slide hole 4h is guided by the shaft portion 50, so that the first piece 41 is accurately disposed at a predetermined position of the winding end portion 21. In this way, in the configuration of this example, the first piece 41 of the busbar 4 is abutted against the winding end portion 21 by simply sliding the busbar 4 fitted on the pin 5 in the X direction.

[0072] Finally, first piece 41 and winding end 21 are joined by welding or the like. At this time, since the movement of bus bar 4 is restricted by pin 5, first piece 41 of bus bar 4 and winding end 21 can be easily joined.

[0073] <Reactor structure installation procedure> The reactor structure α in FIG. 1 is fixed, for example, by screws to an installation target. An example of the installation target is a converter case that houses a converter. A connection terminal for an external device is attached to the reactor structure α that is fixed, for example, by screws, to the installation target. When the connection terminal is fixed, for example, to the terminal block 61, a torque is generated that rotates the bus bar 4 around the screw axis. In the configuration of this example, the movement of the bus bar 4 in the Y1 direction is restricted by the head 51 of the pin 5. This prevents excessive torque from acting on the connection point between the first piece 41 and the winding end 21.

[0074] Effect The reactor structure α of this example does not require screws to fix the bus bar 4 to the reactor 1. In this way, the reactor structure α does not require screws to fix the bus bar 4, and does not require the work of attaching the screws. Therefore, the reactor structure α of this example is excellent in productivity.

[0075] In the reactor structure α of this example, the pin 5 having the head 51 suppresses the vibration of the busbar 4 in the Y direction and the Z direction. Therefore, the stress caused by the vibration of the busbar 4 is unlikely to act on the connection portion between the first piece 41 and the winding end portion 21. Therefore, the reliability of the connection portion is ensured even if the middle portion of the busbar 4 is not screwed as in the conventional technology.

[0076] <Variation 1> The slide hole 4h may be an elongated hole having a uniform width. In this case, the pin 5 that passes through the slide hole 4h is composed of only the shaft portion 50.

[0077] <Variation 2> The pin 5 may be provided in the core 3. For example, the pin may be provided in the outer core portion 32 of the core 3. In that case, it is necessary to ensure insulation between the pin 5 and the bus bar 4. For example, an insulating coating may be formed on at least one of the outer periphery of the pin 5 and the outer periphery of the bus bar 4. When the core 3 is formed of a molded body of a composite material, the pin 5 can be easily formed.

[0078] <Embodiment 2> In the second embodiment, a reactor structure in which the shape of the bus bar 4 is different from that in the first embodiment will be described with reference to Fig. 8. In Fig. 8, only the bus bar 4 is illustrated.

[0079] Similar to the busbar 4 of the first embodiment, the busbar 4 of this example includes a main body piece 40, a first piece 41, and a second piece 42. The shapes of the first piece 41 and the second piece 42 are the same as those of the first embodiment.

[0080] The main body piece 40 has a flat protruding portion 40P that protrudes in the Y1 direction. The thickness direction of the protruding portion 40P coincides with the Z direction. The protruding portion 40P, which is a part of the main body piece 40, is provided with a slide hole 4h having the same shape as in the first embodiment. Since the thickness direction of the protruding portion 40P coincides with the Z direction, the axial direction of the slide hole 4h coincides with the Z direction.

[0081] A pin (not shown) that passes through slide hole 4h of bus bar 4 in this example extends in the Z1 direction. The shape of the pin is the same as the shape of pin 5 shown in FIG.

[0082] In the configuration of this example, vibration of the bus bar 4 in the Z direction is suppressed by the head of the pin, and vibration of the bus bar 4 in the Y direction is suppressed by the shaft of the pin.

[0083] <Embodiment 3> In the third embodiment, a reactor structure α including a case 7 for housing the assembly 10 will be described with reference to Fig. 9. The case 7 is a part of the reactor 1.

[0084] The case 7 includes a resin portion 70 made of an insulating material, at least in a portion that comes into contact with the bus bar 4. The case 7 of this example includes a bottom plate portion 71 on which the assembly 10 is placed, and a side wall portion 72 that covers the side surfaces of the assembly 10. In this example, the entire side wall portion 72 is made of the resin portion 70.

[0085] The side wall 72 in this example is higher than the end of the assembly 10 in the Z1 direction. Therefore, the entire assembly 10 is housed in the case 7. The side wall 72 is provided with a slit 72s that guides the winding end 21 of the assembly 10 housed in the case 7 to the outside of the case 7. The portion of the side wall 72 below the slit 72s is a protruding portion 72P that protrudes relatively in the Y1 direction. The surface of the protruding portion 72P facing the Z1 direction plays the same role as the first surface 6a in the first embodiment. Also, the surface of the protruding portion 72P facing the Y1 direction plays the same role as the second surface 6b in the first embodiment. Therefore, in this example, the protruding portion 72P is provided with a pin 5 and a terminal block 61. The configurations of the pin 5 and the terminal block 61 are the same as those in the first embodiment.

[0086] The bottom plate portion 71 may be made of an insulating material or may be made of metal. The metallic bottom plate portion 71 has excellent rigidity and thermal conductivity. It is preferable that an insulating sheet is disposed between the metallic bottom plate portion 71 and the assembly 10. The bottom plate portion 71 is provided with a plurality of mounting portions 76. The mounting portions 76 of the bottom plate portion 71 are for fixing the case 7 to an installation target. The mounting portions 76 are provided with through holes 76h. The axis of the through holes 76h coincides with the Z direction. Screws for fixing the case 7 to an installation target are disposed in the through holes 76h.

[0087] Even with the configuration of this example, the bus bar 4 can be stably attached to the reactor 1. Therefore, even with the configuration of this example, it is not necessary to fasten the middle portion of the bus bar 4 with a screw.

[0088] <Embodiment 4> <Converter / power conversion device> The reactor structure α according to the embodiment can be used for applications that satisfy the following energization conditions. For example, the energization conditions include a maximum DC current of about 100 A to 1000 A, an average voltage of about 100 V to 1000 V, and an operating frequency of about 5 kHz to 100 kHz. The reactor structure α according to the embodiment can be used as a component of a converter mounted on a vehicle such as an electric vehicle or a hybrid vehicle, or as a component of a power conversion device including the converter.

[0089] 10, a vehicle 1200 such as a hybrid vehicle or an electric vehicle includes a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and a motor 1220 that is driven by power supplied from the main battery 1210 and used for traveling. The motor 1220 is typically a three-phase AC motor, which drives wheels 1250 during traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, the vehicle 1200 includes an engine 1300 in addition to the motor 1220. Although FIG. 10 shows an inlet as a charging point for the vehicle 1200, a form including a plug may also be used.

[0090] The power conversion device 1100 includes a converter 1110 connected to a main battery 1210, and an inverter 1120 connected to the converter 1110 and performing mutual conversion between direct current and alternating current. The converter 1110 shown in this example boosts the input voltage of the main battery 1210, which is about 200V to 300V, to about 400V to 700V when the vehicle 1200 is running, and supplies power to the inverter 1120. During regeneration, the converter 1110 lowers the input voltage output from the motor 1220 via the inverter 1120 to a direct current voltage suitable for the main battery 1210, and charges the main battery 1210. The input voltage is a direct current voltage. When the vehicle 1200 is running, the inverter 1120 converts the DC boosted by the converter 1110 into a predetermined AC and supplies it to the motor 1220. During regeneration, the inverter 1120 converts the AC output from the motor 1220 into DC and outputs it to the converter 1110.

[0091] As shown in FIG. 11, 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 structure 1115, and converts the input voltage by repeatedly switching on and off. The conversion of the input voltage means stepping up and down the voltage here. The switching elements 1111 are power devices such as field effect transistors and insulated gate bipolar transistors. The reactor structure 1115 has a function of smoothing the change when the current increases or decreases due to the switching operation by utilizing the property of a coil that prevents a change in the current flowing through the circuit. The reactor structure 1115 includes the reactor structure α of any one of the first to third embodiments. By including the reactor structure α that is lightweight and has excellent magnetic properties, the power conversion device 1100 and the converter 1110 are lightweight and have excellent conversion efficiency.

[0092] In addition to the converter 1110, the vehicle 1200 includes a power supply converter 1150 connected to the main battery 1210, and an auxiliary power converter 1160 connected to the main battery 1210 and a sub-battery 1230 serving as a power source for the auxiliary devices 1240, and converting the high voltage of the main battery 1210 to a low voltage. The converter 1110 typically performs DC-DC conversion, while the power supply converter 1150 and the auxiliary power converter 1160 perform AC-DC conversion. Some of the power supply converters 1150 perform DC-DC conversion. The reactor structure 1115 of the power supply converter 1150 and the auxiliary power converter 1160 may have the same configuration as the reactor structure α of any one of the first to third embodiments, and may be a reactor structure whose size, shape, and the like are appropriately changed. Furthermore, the reactor structure α of any one of the first to third embodiments can be used for a converter that converts input power and that only boosts the voltage or only drops the voltage. [Explanation of symbols]

[0093] α Reactor structure 1 Reactor 10. Pairing 2 Coil 20 winding portion, 21, 22 winding end portion 3 Cores 3A,3B split core 31 inner core portion, 32 outer core portion 4 Busbar 40 body piece, 40P overhang 41 First piece 42 Second piece, 42h terminal hole 4h slide hole, h1 large hole, h2 small hole 4p first plane 5-pin 50 shaft, 51 head 6 Resin molded part 6a first page, 6b second page 60 Pedestal 61 Terminal block, 61h Screw hole 7 Cases 70 Resin part, 71 Bottom plate part, 72 Side wall part, 72P overhang part 76 mounting part, 76h through hole 8 Support part 8p plane 9. Insulating materials 1100 Power conversion device 1110 converter, 1111 switching element, 1112 drive circuit 1115 Reactor structure, 1120 Inverter 1150 Converter for power supply device, 1160 Converter for auxiliary power supply 1200 vehicles 1210 Main battery, 1220 Motor, 1230 Sub battery 1240 Auxiliary equipment, 1250 Wheels 1300 Engine

Claims

1. a reactor having a coil and a core; A reactor structure including a bus bar electrically connecting the coil and an external device, The reactor is A pin for determining a position of the bus bar with respect to the reactor; a through hole through which a screw for fixing the reactor to an installation target is inserted, The bus bar includes: A first piece connected to an end of a winding of the coil in an overlapping state; A second piece connected to the external device; a main body piece connecting the first piece and the second piece, The main body piece has a long slide hole extending in the X direction, the X direction is a direction in which the winding end portion and the first piece are arranged side by side, the pin is inserted through the slide hole and restricts movement of the bus bar in a direction intersecting the X direction and a protruding direction of the pin; The axis of the through hole coincides with the Y direction or the Z direction, the Y direction intersects with the X direction and is aligned along the extension direction of the winding end portion, The Z direction is a direction intersecting the X direction and the Y direction. Reactor structure.

2. The slide hole includes a large hole portion and a small hole portion that are connected in the X direction, the large hole portion is disposed on the first piece side relative to the small hole portion in the X direction, The reactor structure according to claim 1 , wherein the pin is disposed in the small hole in a state in which the winding end and the first piece are connected to each other.

3. The pin is A shaft portion, A head provided at a tip of the shaft portion, The shaft portion passes through the small hole portion, The head is disposed outside the small hole, The reactor structure according to claim 2 , wherein an outer dimension of the head as viewed in the axial direction of the shaft portion is larger than a width of the small hole.

4. the head has a shape in which the first piece side in the X direction is cut away, The reactor structure according to claim 3 , wherein the large hole portion has a shape that conforms to a shape of the head.

5. The axis of the through hole coincides with the Z direction, The reactor structure according to claim 1 , wherein the pin protrudes in the Y direction.

6. The axis of the through hole coincides with the Z direction, The bus bar has a first plane parallel to an XY plane, The reactor includes a base portion protruding in the Z direction, The reactor structure according to any one of claims 1 to 5, wherein the base portion includes a support portion that supports the first plane parallel to the XY plane.

7. The reactor includes an insulating member that determines a relative position between the coil and the core, The reactor structure according to claim 1 , wherein the pin is provided integrally with the insulating member.

8. The reactor structure according to claim 7 , wherein the insulating member is a resin molded portion that integrates the coil and the core.

9. The reactor includes a case that houses an assembly of the core and the coil, the case includes a resin portion made of an insulating material, The reactor structure according to claim 1 , wherein the pin is provided integrally with the resin portion.

10. A reactor structure comprising the reactor structure according to any one of claims 1 to 9. converter.

11. A converter comprising: Power conversion equipment.

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