Reactor

Abstract

To reduce a load on a busbar and a coil due to vibration in a reactor where a joint between the busbar and coil extension is not molded.SOLUTION: A reactor 4 includes a second bus bar 4e2 that is connected to a connecting end portion 4c3 that is pulled out from a portion of the coil 4c which is exposed from a filling member and is arranged to face the coil 4c with a gap S therebetween. An insulating vibration suppression piece 4f is provided in the gap S between the coil 4c and the second bus bar 4e2 to suppress vibration of the coil 4c and the second bus bar 4e2.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a reactor.

Background Art

[0002] In electric vehicles such as electric cars and hybrid cars, a power conversion device for performing power conversion between a battery and a motor or the like is installed. Such a power conversion device includes a capacitor and a reactor, and for example, converts DC power output from a battery into AC power and supplies power to a motor. Patent Document 1 discloses a reactor provided in such a power conversion device. The reactor disclosed in Patent Document 1 includes a coil attached to a core and a bus bar electrically connected to the coil.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in Patent Document 1, an extension portion is provided which is formed by pulling out an end portion of a winding forming a coil from a main body portion of the coil. The bus bar is joined to the extension portion pulled out so as to protrude from the main body portion in this way. Further, a filling member is filled between the main body portion of the coil and the case in a state where the pulling-out portion of the extension portion is exposed. That is, the coil is fixed to the case in a state where the pulling-out portion of the extension portion is not molded with the filling member. In such a reactor, when external vibration caused by vehicle running or the like is transmitted, the connection portion between the bus bar and the extension portion of the coil is likely to vibrate. For this reason, there is a risk that the load on the bus bar and the coil will increase.

[0005] The present invention has been made in view of the above-described problems, and an object thereof is to reduce the load on a bus bar or a coil due to vibration in a reactor in which a connection portion between a bus bar and an extension portion of a coil is not molded.

Means for Solving the Problems

[0006] As means for solving the above problems, the present invention employs the following configuration.

[0007] A first aspect is a reactor having a case, a core unit housed in the case, a coil disposed around the core unit, and a filling member filled between the coil and the case with a part of the coil exposed, the reactor including a bus bar connected to an extension portion drawn from a portion of the coil exposed from the filling member and disposed opposite to the coil with a gap therebetween, and an insulating vibration suppression portion disposed in the gap between the coil and the bus bar to suppress vibration of at least one of the coil and the bus bar.

[0008] A second aspect is a configuration in which, in the first aspect, the vibration suppression portion is integrally formed with either the core unit or the filling member.

[0009] A third aspect is a configuration in which, in the first aspect, the core unit has a conductive core and a resin core cover covering the core, and the vibration suppression portion is integrally formed with the core cover.

[0010] A fourth aspect is a configuration in which, in any one of the first to third aspects, the vibration suppression portion is in contact with at least one of the coil and the bus bar.

[0011] The fifth aspect is that in any of the first to fourth aspects, the coil has a main body portion in which a winding is wound around a cylindrical body, and an extension portion formed by a tip portion of the winding and extending in a direction along the axial center of the cylindrical body from the main body portion. A portion where the root of the extension portion of the main body portion is connected and the bus bar are arranged to face each other in parallel, and the vibration suppression portion is arranged in a gap formed between the portion where the root of the extension portion of the main body portion is connected and the bus bar.

Advantages of the Invention

[0012] According to the present invention, an insulating vibration suppression portion is arranged in a gap between the coil and the bus bar. When the connection portion between the extension portion of the coil and the bus bar vibrates or attempts to vibrate, the movement of the coil or the bus bar is restricted by the vibration suppression portion. Therefore, according to the present invention, vibration of the connection portion between the extension portion of the coil and the bus bar can be suppressed. Thus, according to the present invention, in a reactor in which the connection portion between the bus bar and the extension portion of the coil is not molded, it is possible to reduce the load on the bus bar and the coil due to vibration.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Modes for Carrying Out the Invention

[0014] Hereinafter, with reference to the drawings, an embodiment of the reactor according to the present invention will be described.

[0015] FIG. 1 is an exploded perspective view showing a schematic configuration of a power conversion device 1 including a reactor 4 of the present embodiment. The power conversion device 1 is mounted on a vehicle such as an electric vehicle and is provided between a motor (load) (not shown) and a battery. As shown in FIG. 1, such a power conversion device 1 includes an intelligent power module 2, a capacitor 3, a reactor 4, a DCDC converter 5, and a main body case 6.

[0016] The intelligent power module 2 includes a power module 10, a gate driver board 11, an ECU board 12, and the like. The power module 10 includes a plurality of power devices 10a having power semiconductor elements, a resin-made power module case 10b that houses these power devices 10a, and a bus bar 10c connected to the power devices 10a. Further, the power module 10 includes an insulating resin member that prevents a short circuit of the bus bar 10c, a water jacket for cooling, and the like.

[0017] The gate driver board 11 is a board provided with a gate driver that generates drive signals for a boost - buck converter or an inverter formed by the power device 10a. Such a gate driver board 11 is laminated on the power module 10. The ECU board 12 is a board provided with an ECU (Electronic Control Unit) that controls the gate driver board 11. This ECU board 12 is laminated on the gate driver board 11.

[0018] The capacitor 3 is connected to the intelligent power module 2 and is disposed laterally of the power module 10. The reactor 4 of the present embodiment is disposed below the intelligent power module 2. The configuration of the reactor 4 of the present embodiment will be described in detail later. The DCDC converter 5 is disposed laterally of the reactor 4 and below the intelligent power module 2. Note that the DCDC converter 5 converts the battery power into a voltage suitable for the surrounding electronic components (such as the electronic components mounted on the gate driver board 11 and the ECU board 12).

[0019] The main body case 6 is a case that houses the intelligent power module 2, the capacitor 3, the reactor 4, and the DCDC converter 5, and includes an upper case 6a, a central case 6b, and a lower case 6c. These upper case 6a, central case 6b, and lower case 6c are connected in a dividable manner in the stacking direction of the power module 10, the gate driver board 11, and the ECU board 12. The upper case 6a covers the intelligent power module 2 from the side of the ECU board 12 and is fastened to the central case 6b. The central case 6b covers the periphery of the intelligent power module 2, the capacitor 3, the reactor 4, and the DCDC converter 5. The lower case 6c covers the reactor 4 and the DCDC converter 5 from below, and is provided with a connection connector for connecting the intelligent power module 2 and a motor (not shown), and is fastened to the central case 6b.

[0020] FIG. 2 is a schematic plan view of the reactor 4 of the present embodiment. Further, FIG. 3 is a sectional view taken along line A-A of FIG. 2. In FIG. 2, the lid portion 4a2 of the reactor case 4a is omitted. As shown in FIGS. 2 and 3, the reactor 4 of the present embodiment includes a reactor case 4a, a core unit 4b, a coil 4c, a filling member 4d, a bus bar 4e, and a vibration suppression piece 4f (vibration suppression portion).

[0021] The reactor case 4a is a case that houses the core unit 4b, the coil 4c, the filling member 4d, and the vibration suppression piece 4f. This reactor case 4a has a main body portion 4a1 and a lid portion 4a2. The main body portion 4a1 is formed in a substantially square container shape with one side open, and houses the core unit 4b, the coil 4c, the filling member 4d, and the vibration suppression piece 4f inside. The lid portion 4a2 is detachably attached to the main body portion 4a1 and opens and closes the open surface of the main body portion 4a1. Although the reactor case 4a is not shown in FIGS. 2 and 3, it has structures such as the attachment portion of the core unit 4b and the fastening portion between the main body portion 4a1 and the lid portion 4a2.

[0022] The core unit 4b has, for example, as shown in FIG. 3, a core 4b1 and a core cover 4b2. The core 4b1 is a core material formed of a conductive metal and is disposed in an inserted state in the coil 4c. In the present embodiment, the core unit 4b has two cores 4b1. The core cover 4b2 is a resin cover member that covers the core 4b1. The core cover 4b2 is provided so as to cover each core 4b1. This core cover 4b2 is fastened to the main body portion 4a1 of the reactor case 4a by screws or the like (not shown).

[0023] The coil 4c is formed by winding a winding 4c1 and has a main body portion 4c2 and a connection end portion 4c3 (extension portion). In the present embodiment, two coils 4c are provided. Each coil 4c has two main body portions 4c2 and two connection end portions 4c3. The main body portion 4c2 is a portion where the winding 4c1 is wound around a cylindrical body, and the core 4b1 is inserted with the core cover 4b2 disposed therebetween. As shown in FIGS. 2 and 3, different cores 4b1 are inserted into the two main body portions 4c2 provided in one coil 4c.

[0024] The connection end portion 4c3 is formed by the tip of the winding 4c1 and is the portion joined to the bus bar 4e. As shown in FIG. 2, this connection end portion 4c3 is drawn out from the main body portion 4c2 and extends in the direction along the axis L of the cylindrical main body portion 4c2. In this way, the connection end portion 4c3 is connected so as to bend with respect to the end face of the cylindrical main body portion 4c2. Such a connection end portion 4c3 is arranged so as to be drawn out from the upper portion of the main body portion 4c2 (the lid portion 4a2 side of the reactor case 4a).

[0025] The filling member 4d is provided so as to embed the lower portion of the coil 4c (the bottom side of the main body portion 4a1 of the reactor case 4a), and is a resin member filled between the coil 4c and the main body portion 4a1 of the reactor case 4a. That is, the filling member 4d is filled between the coil 4c and the main body portion 4a1 of the reactor case 4a with the upper portion of the coil 4c exposed. That is, the filling member 4d molds the lower portion of the main body portion 4c2 with the upper portion of the main body portion 4c2 to which the connection end portion 4c3 is connected exposed.

[0026] The bus bar 4e is a wiring member for connecting the coil 4c and the outside of the reactor 4. One end of this bus bar 4e is joined to the connection end portion 4c3 of the coil 4c. Also, an external connection terminal for connecting the reactor 4 to an external device is provided at the other end of the bus bar 4e.

[0027] In the present embodiment, a plurality of bus bars 4e are provided. As shown in FIG. 2, the reactor 4 of the present embodiment includes a first bus bar 4e1 and a second bus bar 4e2 as the bus bars 4e. These first bus bar 4e1 and second bus bar 4e2 are joined to different connection end portions 4c3.

[0028] The second busbar 4e2, which is one of the busbars 4e, is disposed opposite the winding 4c1 of the main body 4c2 that is continuous with the connection end 4c3 to which the second busbar 4e2 is joined. More specifically, in the main body 4c2 from which the connection end 4c3 to which the second busbar 4e2 is connected is drawn, the second busbar 4e2 is disposed opposite the end of the winding 4c1 that forms the main body 4c2 (hereinafter referred to as the main body end 4c4). That is, the second busbar 4e2 is disposed opposite the main body end 4c4 (the part of the main body 4c2 to which the root of the connection end 4c3 is connected) to which the connection end 4c3 is bent and connected, with a gap S therebetween. For comparison, the first busbar 4e1 is not disposed opposite the main body end 4c4 of the main body 4c2 from which the connection end 4c3 to which the first busbar 4e1 is joined is drawn.

[0029] As shown in Fig. 2, the vibration suppressing piece 4f is disposed in a gap S formed between the first bus bar 4e1 and the main body terminal end 4c4 of the main body portion 4c2. Fig. 4(a) is a schematic enlarged perspective view including the vibration suppressing piece 4f. Fig. 4(b) is a view in which the second bus bar 4e2 of Fig. 4(a) is omitted. Fig. 5 is a cross-sectional view taken along line BB of Fig. 4(a). As shown in these figures, the vibration suppressing piece 4f is a piece-like portion provided to protrude from the core cover 4b2 of the core unit 4b.

[0030] The vibration suppressing piece 4f is an insulating member made of resin and is provided integrally with the core cover 4b2. For example, by forming the vibration suppressing piece 4f from the same material as the core cover 4b2, it becomes possible to integrally mold the vibration suppressing piece 4f at the same time as the core cover 4b2. However, it is also possible to form the vibration suppressing piece 4f from a material different from that of the core cover 4b2. It is also possible to join the vibration suppressing piece 4f to the core cover 4b2 after the core cover 4b2 is formed.

[0031] As shown in Fig. 5, the vibration suppression piece 4f has a base portion 4f1 and a tip portion 4f2. The base portion 4f1 of the vibration suppression piece 4f has a larger thickness dimension than the tip portion 4f2 and functions as a base portion that supports the tip portion 4f2. The tip portion 4f2 is erected on the base portion 4f1 and is disposed between the first bus bar 4e1 and the main body end portion 4c4 of the main body portion 4c2. Note that, as shown in Fig. 6(a), the vibration suppression piece 4f may be in contact with the main body end portion 4c4 of the coil 4c. Further, as shown in Fig. 6(b), the vibration suppression piece 4f may be in contact with the second bus bar 4e2. Further, as shown in Fig. 6(c), the vibration suppression piece 4f may be in contact with both the main body end portion 4c4 of the coil 4c and the second bus bar 4e2.

[0032] When the connection portion between the connection end portion 4c3 of the coil 4c and the second bus bar 4e2 vibrates or attempts to vibrate, such a vibration suppression piece 4f restricts the movement of the connection end portion 4c3 of the coil 4c and the second bus bar 4e2. That is, the vibration suppression piece 4f suppresses the vibration of the connection end portion 4c3 and the second bus bar 4e2.

[0033] The reactor 4 of the present embodiment as described above includes a reactor case 4a, a core unit 4b housed in the reactor case 4a, and a coil 4c disposed around the core unit 4b. Further, the reactor 4 of the present embodiment has a filling member 4d filled between the coil 4c and the reactor case 4a in a state where a part of the coil 4c is exposed.

[0034] Further, the reactor 4 of the present embodiment has a second bus bar 4e2 that is connected to a connection end portion 4c3 drawn from a portion of the coil 4c exposed from the filling member 4d and is disposed opposite to the coil 4c with a gap S therebetween. Further, the reactor 4 of the present embodiment includes an insulating vibration suppression piece 4f disposed in the gap S between the coil 4c and the second bus bar 4e2 to suppress the vibration of at least one of the coil 4c and the second bus bar 4e2.

[0035] In the reactor 4 of this embodiment, an insulating vibration suppression piece 4f is disposed in the gap S between the coil 4c and the second bus bar 4e2. When the connection portion between the connection end portion 4c3 of the coil 4c and the second bus bar 4e2 vibrates or attempts to vibrate, the movement of the coil 4c or the second bus bar 4e2 is restricted by the vibration suppression piece 4f.

[0036] Therefore, according to the reactor 4 of this embodiment, the vibration of the connection portion between the connection end portion 4c3 of the coil 4c and the second bus bar 4e2 can be suppressed. Thus, according to the reactor 4 of this embodiment, in a reactor in which the connection portion between the second bus bar 4e2 and the connection end portion 4c3 of the coil 4c is not molded, it is possible to reduce the load on the second bus bar 4e2 and the coil 4c due to vibration.

[0037] Also, since the insulating vibration suppression piece 4f is disposed in the gap S between the coil 4c and the second bus bar 4e2, it is possible to secure an insulation distance between the coil 4c and an intermediate portion of the second bus bar 4e2.

[0038] Also, in the reactor 4 of this embodiment, the vibration suppression piece 4f is integrally formed with the core unit 4b. Therefore, the vibration suppression piece 4f can be supported by the core unit 4b, and there is no need to separately provide a support portion for supporting the vibration suppression piece 4f. Thus, it is possible to miniaturize the reactor 4 of this embodiment.

[0039] Also, in the reactor 4 of this embodiment, the core unit 4b has a conductive core 4b1 and a resin core cover 4b2 covering the core 4b1. Further, the vibration suppression piece 4f is integrally formed with the core cover 4b2. Therefore, the vibration suppression piece 4f can be formed simultaneously with the core cover 4b2, and it is possible to easily form the reactor 4 provided with the vibration suppression piece 4f.

[0040] Further, in the reactor 4 of the present embodiment, the vibration suppression piece 4f may be in contact with the coil 4c or the second bus bar 4e2. By the vibration suppression piece 4f being in contact with the coil 4c or the second bus bar 4e2, compared with the case where the vibration suppression piece 4f is separated from the coil 4c and the second bus bar 4e2, it becomes possible to more reliably regulate the movement due to the vibration of the coil 4c or the second bus bar 4e2. Therefore, according to the reactor 4 of the present embodiment, by the vibration suppression piece 4f being in contact with the coil 4c or the second bus bar 4e2, it becomes possible to further reduce the load on the coil 4c or the second bus bar 4e2 due to vibration.

[0041] Further, in the reactor 4 of the present embodiment, the coil 4c has a main body portion 4c2 in which the winding is wound around a cylindrical body, and a connection end portion 4c3 formed by the tip end portion of the winding and extending in a direction along the axial center L of the cylindrical body from the main body portion 4c2. Also, a portion (main body end portion 4c4) where the root of the connection end portion 4c3 of the main body portion 4c2 is connected and the second bus bar 4e2 are arranged to face each other in parallel. Further, the vibration suppression piece 4f is arranged in a gap S formed between the main body end portion 4c4 and the second bus bar 4e2.

[0042] In the configuration where the main body end portion 4c4 and the second bus bar 4e2 are arranged to face each other, it was confirmed that if the vibration suppression piece 4f is not provided, the load due to vibration on the second bus bar 4e2 is large. In the reactor 4 of the present embodiment, since the vibration suppression piece 4f is arranged in the gap S formed between the main body end portion 4c4 and the second bus bar 4e2, it becomes possible to prevent the occurrence of a portion with a large load.

[0043] As described above, the preferred embodiments of the present invention have been described with reference to the accompanying drawings, but it goes without saying that the present invention is not limited to the above embodiments. The various shapes, combinations, etc. of the respective constituent members shown in the above-described embodiments are merely examples, and various modifications can be made based on design requirements and the like without departing from the spirit of the present invention.

[0044] For example, in the above-described embodiment, the configuration in which the vibration suppression piece 4f is integrally provided with the core cover 4b2 has been described. However, the present invention is not limited to this. For example, the vibration suppression piece 4f may be integrally provided with the filling member 4d. Further, a vibration suppression piece 4f separate from the core cover 4b2 and the filling member 4d may be provided.

[0045] Also, in the above-described embodiment, the configuration including the sheet-like vibration suppression piece 4f has been described. However, the present invention is not limited to this. For example, a vibration suppression piece 4f having a shape different from a sheet shape such as a block shape may be provided.

[0046] Also, in the above-described embodiment, the configuration in which the vibration suppression piece 4f is installed only between the second bus bar 4e2 disposed opposite to the main body end portion 4c4 and the main body portion 4c2 of the coil 4c has been described. However, the present invention is not limited to this. For example, it is also possible to adopt a configuration in which the vibration suppression piece 4f is installed in the gap between the coil 4c and the first bus bar 4e1.

[0047] Also, in the above-described embodiment, the configuration in which the vibration suppression piece 4f is in contact with the second bus bar 4e2 has been adopted. However, the present invention is not limited to this. For example, when the coil 4c or the second bus bar 4e2 is not vibrating, it is also possible to adopt a configuration in which the vibration suppression piece 4f is not in contact with the coil 4c and the second bus bar 4e2. In such a case, for example, the vibration suppression piece 4f is arranged so as to be in contact with the coil 4c and the second bus bar 4e2 in a state where the amplitude is small so that the amplitude does not increase when the coil 4c or the second bus bar 4e2 is vibrating.

[0048] Also, in the present embodiment, it is also possible to adopt a configuration in which the vibration suppression piece 4f is in contact with the main body end portion 4c4 of the coil 4c without contacting the second bus bar 4e2. Further, it is also possible to adopt a configuration in which the vibration suppression piece 4f is in contact with both the main body end portion 4c4 and the second bus bar 4e2.

Explanation of Reference Numerals

[0049] 1... Power conversion device, 2... Intelligent power module, 3... Capacitor, 4... Reactor, 4a... Reactor case (case), 4b... Core unit, 4b1... Core, 4b2... Core cover, 4c... Coil, 4c1... winding, 4c2... Body part, 4c3... Connection end part, 4c4... Body end part, 4d... Filling member, 4e... Bus bar, 4e1... First bus bar, 4e2... Second bus bar, 4f... Vibration suppression piece (vibration suppression piece), 4f1... Root part, 4f2... Tip part, L... Axis center, S... Gap

Claims

1. A reactor comprising a case, a core unit housed in the case, a coil disposed around the core unit, and a filling member filled between the coil and the case with a part of the coil exposed, a bus bar connected to an extension portion drawn from a portion of the coil exposed from the filling member and disposed opposite to the coil with a gap therebetween, and an insulating vibration suppression portion disposed in the gap between the coil and the bus bar for suppressing vibration of at least one of the coil and the bus bar, wherein, the vibration suppression portion is integrally formed with either the core unit or the filling member. The reactor is characterized by the above.

2. A reactor comprising a case, a core unit housed in the case, a coil disposed around the core unit, and a filling member filled between the coil and the case with a part of the coil exposed, a bus bar connected to an extension portion drawn from a portion of the coil exposed from the filling member and disposed opposite to the coil with a gap therebetween, and an insulating vibration suppression portion disposed in the gap between the coil and the bus bar for suppressing vibration of at least one of the coil and the bus bar, wherein, the core unit has a conductive core and a resin core cover covering the core, and the vibration suppression portion is integrally formed with the core cover. The reactor is characterized by the above.

3. A reactor comprising a case, a core unit housed in the case, a coil disposed around the core unit, and a filling member filled between the coil and the case with a part of the coil exposed, a bus bar connected to an extension portion drawn from a portion of the coil exposed from the filling member and disposed opposite to the coil with a gap therebetween, and an insulating vibration suppression portion disposed in the gap between the coil and the bus bar for suppressing vibration of at least one of the coil and the bus bar, wherein, the coil has a main body portion in which a winding is wound around a cylindrical body, and an extension portion formed by a tip portion of the winding and extending in a direction along the axis of the cylindrical body from the main body portion. The coil is characterized by the above. The part where the root of the extending part of the main body is connected and the bus bar are arranged to face each other in parallel. The vibration suppression part is arranged in the gap formed between the part where the root of the extending part of the main body is connected and the bus bar. A reactor characterized by the above.

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