reactor

Abstract

To improve reactor assembly workability.SOLUTION: A reactor includes coils for each phase aligned in a predetermined phase arrangement direction, and a first bus bar extending in the phase arrangement direction. Each coil includes a first terminal that is a part of the rectangular wire portion of the coil. The direction perpendicular to the surface of the first terminal is the phase arrangement direction. The first bus bar includes a connection portion for each coil. The direction perpendicular to the surface of each connection portion is the phase arrangement direction. Each connection portion of the first bus bar abuts against the first terminal of the coil corresponding to that connection portion in the phase arrangement direction.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a reactor including a plurality of coils. [Background technology]

[0002] Some reactors include a plurality of coils and bus bars electrically connected to the coils. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-081963 Summary of the Invention [Problem to be solved by the invention]

[0004] The present inventors have focused on the fact that it is preferable for such a reactor to be as easy to assemble as possible. The present invention has been made in view of the above circumstances, and an object of the present invention is to improve the ease of assembly of a reactor. [Means for solving the problem]

[0005] The present inventors have discovered that reactor assembly workability can be improved by devising the shape of the bus bar portion electrically connected to the terminals of each coil and the shape of the terminals of each coil, and have arrived at the present invention. The present invention relates to the following reactors (1) to (4).

[0006] (1) A reactor including a coil provided for each phase arranged in a predetermined phase arrangement direction and a first bus bar extending in the phase arrangement direction, Each of the coils has a first terminal that is a part of a rectangular wire portion of the coil, and the surface perpendicular direction of the first terminal is the arrangement direction, the first bus bar includes a connection portion for each of the coils, and a surface-perpendicular direction of each of the connection portions is the arrangement direction; Each of the connection portions of the first bus bar abuts against the first terminal of the coil corresponding to the connection portion in the arrangement direction. Reactor.

[0007] According to this configuration, by pressing the first bus bars in the arranging direction, each connection portion of the first bus bar can be electrically connected to the first terminal of the coil corresponding to the connection portion, thereby improving the workability of assembling the reactor.

[0008] (2) The arranging direction is a horizontal direction, For each of the phases, the coils include a first coil and a second coil that are arranged in a horizontal direction perpendicular to the phase arrangement direction and are electrically connected in parallel to each other, In each of the phases, a portion of the first coil on the side of the first terminal and a portion of the second coil on the side of the first terminal each extend upward and then extend horizontally toward directly above the first coil, so that the first terminal of the first coil and the first terminal of the second coil are located directly above the first coil, The first bus bar is electrically connected to the first terminal of each of the first coils and the first terminal of each of the second coils directly above the first coils. The reactor according to (1) above.

[0009] According to this configuration, the first terminal of the first coil and the first terminal of the second coil are gathered directly above the first coil in each phase, so that the first bus bar can be electrically connected to the first terminal of the first coil and the first terminal of the second coil directly above the first coil in each phase.

[0010] (3) A second bus bar is provided for each of the phases, Each of the coils has a second terminal; In each of the phases, a portion of the first coil on the second terminal side and a portion of the second coil on the second terminal side each extend upward and then extend horizontally toward directly above the second coil, so that the second terminal of the first coil and the second terminal of the second coil are located directly above the second coil, In each of the phases, the second bus bar is electrically connected to the second terminal of the second coil and the second terminal of the first coil directly above the second coil. The reactor according to (2) above.

[0011] According to this configuration, the second terminals of the first coil and the second coil are gathered directly above the second coil in each phase, so that the second bus bar can be electrically connected to the second terminals of the second coil and the first coil directly above the second coil in each phase.

[0012] (4) Each of the first coils and each of the second coils have the same shape. The reactor according to (2) or (3) above.

[0013] According to this configuration, by making each of the first coils and each of the second coils have the same shape, the number of types of components of the reactor can be reduced, and the reactor can be configured simply. [Effects of the Invention]

[0014] As described above, the configuration (1) can improve the workability of assembling the reactor. Furthermore, the configurations (2) to (4) that refer to the configuration (1) can provide additional effects. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a perspective view showing a reactor of a first embodiment. [Figure 2] FIG. 2 is a plan view showing a reactor. [Figure 3] FIG. 1 is a circuit diagram showing a circuit including a reactor. [Figure 4] FIG. 2 is a plan view showing an initial stage of assembly of the reactor. [Figure 5] FIG. [Figure 6] FIG. 5 is a plan view showing a subsequent stage to FIG. 4 during the assembly. [Figure 7] FIG. 10 is a perspective view showing a coil in a reactor of a comparative example. [Figure 8] FIG. 2 is a plan view showing the reactor when assembled. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the present invention is not limited to the following embodiments and can be appropriately modified and implemented within the scope of the present invention.

[0017] [First embodiment] As shown in FIG. 1, the reactor Rt includes a housing Hs, a core Cr, six coils cU1 to cW2, a first bus bar b1, and three second bus bars bU, bV, and bW.

[0018] The six coils cU1 to cW2 include a U-phase first coil cU1, a U-phase second coil cU2, a V-phase first coil cV1, a V-phase second coil cV2, a W-phase first coil cW1, and a W-phase second coil cW2.

[0019] Hereinafter, the U-phase first coil cU1 and the U-phase second coil cU2 will be referred to as "U-phase coils cU1, cU2." The V-phase first coil cV1 and the V-phase second coil cV2 will be referred to as "V-phase coils cV1, cV2." The W-phase first coil cW1 and the W-phase second coil cW2 will be referred to as "W-phase coils cW1, cW2." The U-phase first coil cU1, the V-phase first coil cV1, and the W-phase first coil cW1 will be referred to as "first coils cU1, cV1, cW1." The U-phase second coil cU2, the V-phase second coil cV2, and the W-phase second coil cW2 will be referred to as "second coils cU2, cV2, cW2." One terminal of each of the coils cU1 to cW2 will be referred to as "first terminal e1," and the other terminal will be referred to as "second terminal e2."

[0020] As shown in Fig. 3, the reactor Rt constitutes, for example, a part of a three-phase boost chopper Tc. The three-phase boost chopper Tc boosts the voltage from, for example, a battery Bt and supplies it to a drive unit Du. In addition to the reactor Rt, the three-phase boost chopper Tc includes three semiconductor switches sU, sV, and sW, three diodes dU, dV, and dW, and a smoothing capacitor Cp. The three semiconductor switches sU, sV, and sW consist of a U-phase switch sU, a V-phase switch sV, and a W-phase switch sW. The three diodes dU, dV, and dW consist of a U-phase diode dU, a V-phase diode dV, and a W-phase diode dW.

[0021] The positive terminal BtP of the battery Bt is electrically connected to the first terminal e1 of each of the six coils cU1 to cW2 via the first bus bar b1, so that the six coils cU1 to cW2 are electrically connected in parallel with one another.

[0022] The second terminal e2 of each of the two U-phase coils cU1, cU2 is electrically connected to the anode terminal of the U-phase diode dU via the U-phase bus bar bU and is also electrically connected to the positive terminal of the U-phase switch sU. The second terminal e2 of each of the two V-phase coils cV1, cV2 is electrically connected to the anode terminal of the V-phase diode dV via the V-phase bus bar bV and is also electrically connected to the positive terminal of the V-phase switch sV. The second terminal e2 of each of the two W-phase coils cW1, cW2 is electrically connected to the anode terminal of the W-phase diode dW via the W-phase bus bar bW and is also electrically connected to the positive terminal of the W-phase switch sW.

[0023] The cathode terminals of the three diodes dU, dV, and dW are electrically connected to the positive terminal of the smoothing capacitor Cp and the positive terminal DuP of the drive unit Du. The negative terminals of the three switches sU, sV, and sW are electrically connected to the negative terminal BtN of the battery Bt, the negative terminal of the smoothing capacitor Cp, and the negative terminal DuN of the drive unit Du.

[0024] Hereinafter, as shown in Figure 1, two predetermined directions that intersect at right angles in a horizontal plane will be referred to as the "X direction" and the "Y direction." One side in the X direction will be referred to as the "X- side," and the opposite side will be referred to as the "X+ side." One side in the Y direction will be referred to as the "Y- side," and the opposite side will be referred to as the "Y+ side."

[0025] The core Cr is a magnetic member and is formed, for example, as two parts separated by a central portion in the Y direction. The six coils cU1 to cW2 are fitted onto the core Cr. As a result, the three first coils cU1, cV1, and cW1 are aligned in the X direction. The three second coils cU2, cV2, and cW2 are aligned in the X direction on the Y-side of the three first coils cU1, cV1, and cW1. In other words, the three phases, U, V, and W, are aligned in the X direction. Therefore, the "X direction" may be interpreted as the "phase alignment direction." The housing Hs houses the core Cr and the six coils cU1 to cW2 inside.

[0026] The six coils cU1 to cW2 are all identical in shape. Each of the six coils cU1 to cW2 is mainly made of a rectangular wire-shaped conductor extending in a winding shape. In each of the six coils cU1 to cW2, a first terminal e1 is provided at one end of the rectangular wire-shaped conductor, and a second terminal e2 is provided at the other end of the rectangular wire-shaped conductor.

[0027] 1, the portion of each of the three first coils cU1, cV1, and cW1 on the side of the first terminal e1 extends upward and then extends horizontally directly above the first coil cU1, cV1, and cW1. On the other hand, the portion of each of the second coils cU2, cV2, and cW2 on the side of the first terminal e1 extends upward and then extends horizontally directly above the first coil cU1, cV1, and cW1 of the same phase.

[0028] Therefore, in each of the three phases, the first terminal e1 of the first coils cU1, cV1, and cW1 and the first terminal e1 of the second coils cU2, cV2, and cW2 are located directly above the first coils cU1, cV1, and cW1, as shown in Fig. 2. The direction perpendicular to the surface of the first terminal e1 of each of the three first coils cU1, cV1, and cW1 and the direction perpendicular to the surface of the first terminal e1 of each of the three second coils cU2, cV2, and cW2 are both in the X direction.

[0029] 1, the portion of each of the three first coils cU1, cV1, and cW1 on the second terminal e2 side extends upward and then extends horizontally directly above the second coil cU2, cV2, and cW2 of the same phase, while the portion of each of the second coils cU2, cV2, and cW2 on the second terminal e2 side extends upward and then extends horizontally directly above the second coil cU2, cV2, and cW2.

[0030] Therefore, in each of the three phases, the second terminal e2 of the first coil cU1, cV1, cW1 and the second terminal e2 of the second coil cU2, cV2, cW2 are located directly above the second coil cU2, cV2, cW2, as shown in Fig. 2. The direction perpendicular to the surface of the second terminal e2 of each of the three first coils cU1, cV1, cW1 and the direction perpendicular to the surface of the second terminal e2 of each of the three second coils cU2, cV2, cW2 are both in the X direction.

[0031] As shown in FIG. 1, the first bus bar b1 is disposed so as to straddle the three first coils cU1, cV1, and cW1. The first bus bar b1 is a conductive member and includes a base b1A and six protrusions b1B. The base b1A extends in the X direction. Each protrusion b1B is a rectangular wire-shaped portion protruding upward from the base b1A. The upper end of each protrusion b1B forms a connection portion b1C. Therefore, the first bus bar b1 has six connection portions b1C. The plane-perpendicular direction of each connection portion b1C is the X direction.

[0032] Each of the six connection portions b1C of the first busbar b1 abuts against the first terminal e1 of the corresponding coil cU1-cW2 from the X- side to the X+ side. That is, for example, a certain connection portion b1C of the first busbar b1 abuts against the first terminal e1 of the U-phase first coil cU1 from the X- side to the X+ side. Also, for example, another connection portion b1C of the first busbar b1 abuts against the first terminal e1 of the U-phase second coil cU2 from the X- side to the X+ side.

[0033] The U-phase busbar bU is disposed directly above the U-phase second coil cU2. The U-phase busbar bU is a conductive member and includes a base b2A and two protrusions b2B. The base b2A extends in the Y direction. Each protrusion b2B is a rectangular wire-shaped portion that protrudes upward from the base b2A. The upper end of each protrusion b2B forms a connection portion b2C. Therefore, the U-phase busbar bU has two connection portions b2C. The plane-perpendicular direction of each connection portion b2C is the X direction.

[0034] Each of the two connection portions b2C of the U-phase busbar bU abuts against the second terminal e2 of the corresponding U-phase coil cU1, cU2 from the X+ side to the X- side. That is, one connection portion b2C of the U-phase busbar bU abuts against the second terminal e2 of the first U-phase coil cU1 from the X+ side to the X- side. Furthermore, the other connection portion b2C of the U-phase busbar bU abuts against the second terminal e2 of the second U-phase coil cU2 from the X+ side to the X- side.

[0035] The description of the V-phase busbar bV is similar to the description of the U-phase busbar bU above, except that "U-phase" is replaced with "V-phase" and the corresponding symbols are used. The description of the W-phase busbar bW is similar to the description of the U-phase busbar bU above, except that "U-phase" is replaced with "W-phase" and the corresponding symbols are used.

[0036] Next, a method for manufacturing the reactor Rt described above will be described. First, as shown in Fig. 4, the six coils cU1 to cW2 are fitted onto the core Cr at predetermined positions. As a result, in each of the three phases, the first terminals e1 of the first coils cU1, cV1, and cW1 and the first terminals e1 of the second coils cU2, cV2, and cW2 are arranged directly above the first coils cU1, cV1, and cW1. In addition, in each of the three phases, the second terminals e2 of the first coils cU1, cV1, and cW1 and the second terminals e2 of the second coils cU2, cV2, and cW2 are arranged directly above the second coils cU2, cV2, and cW2.

[0037] Next, as shown in FIG. 6, the first bus bar b1 is positioned so as to straddle the three first coils cU1, cV1, and cW1. At this time, each connection portion b1C of the first bus bar b1 is positioned closer to the X- side than the first terminals e1 of the coils cU1 to cW2 corresponding to that connection portion b1C. From this state, the first bus bar b1 is moved from the X- side to the X+ side. This causes each of the six connection portions b1C of the first bus bar b1 to abut against the first terminals e1 of the coils cU1 to cW2 corresponding to that connection portion b1C. This electrically connects the first bus bar b1 to the first terminals e1 of the six coils cU1 to cW2. In this state, the first bus bar b1 is fixed to the housing Hs or the like, and each of the six connection portions b1C of the first bus bar b1 is welded to the first terminals e1 of the coils cU1 to cW2 corresponding to that connection portion b1C.

[0038] From this state, the three second busbars bU, bV, and bW are attached as shown in FIG. 2. That is, the U-phase busbar bU is positioned directly above the U-phase second coil cU2. At this time, each connection portion b2C of the U-phase busbar bU is positioned closer to the X+ side than the second terminals e2 of the U-phase coils cU1 and cU2 corresponding to that connection portion b2C. From this state, the U-phase busbar bU is moved toward the X- side. This causes each of the two connection portions b2C of the U-phase busbar bU to abut against the second terminals e2 of the U-phase coils cU1 and cU2 corresponding to that connection portion b2C. This electrically connects the U-phase busbar bU to the second terminals e2 of the two U-phase coils cU1 and cU2. In this state, the U-phase bus bar bU is fixed to the housing Hs or the like, and the two connection portions b2C of the U-phase bus bar bU are welded to the second terminals e2 of the U-phase coils cU1, cU2 corresponding to the connection portions b2C.

[0039] The description of the installation of the V-phase busbar bV is similar to the description of the installation of the U-phase busbar bU above, except that "U-phase" is replaced with "V-phase" and the reference numerals are replaced with the corresponding symbols. The description of the installation of the W-phase busbar bW is similar to the description of the installation of the U-phase busbar bU above, except that "U-phase" is replaced with "W-phase" and the reference numerals are replaced with the corresponding symbols.

[0040] Hereinafter, the comparative example will be defined as an example where the state of this embodiment has been changed as follows. That is, in this comparative example, as shown in Fig. 7, the plane-perpendicular direction of the first terminals e1 of each of the six coils cU1 to cW2 is the Y direction instead of the X direction. Therefore, as shown in Fig. 8, the plane-perpendicular direction of each of the six connection portions b1C of the first bus bar b1 is also the Y direction instead of the X direction. Therefore, each of the six connection portions b1C of the first bus bar b1 abuts against the first terminals e1 of the coils cU1 to cW2 corresponding to that connection portion b1C from the Y+ side to the Y- side.

[0041] The configuration and effects of this embodiment will be summarized below in comparison with comparative embodiments.

[0042] In the comparative example shown in Fig. 8, the plane-perpendicular direction of the first terminals e1 of the six coils cU1 to cW2 and the plane-perpendicular direction of each of the six connection portions b1C of the first bus bar b1 are in the Y direction, i.e., perpendicular to the phase arrangement direction. Therefore, it is necessary to move the first bus bar b1 in the direction perpendicular to the phase arrangement direction so that each of the six connection portions b1C of the first bus bar b1 contacts the first terminals e1 of the coils cU1 to cW2 corresponding to that connection portion b1C. This can make the contacting task difficult.

[0043] In this embodiment, as shown in Fig. 6, the plane-perpendicular direction of the first terminals e1 of the six coils cU1 to cW2 and the plane-perpendicular direction of the six connection portions b1C of the first bus bar b1 are in the X direction, i.e., the phase arrangement direction. Therefore, by moving the first bus bar b1 in the phase arrangement direction, each of the six connection portions b1C of the first bus bar b1 can be brought into contact with the first terminals e1 of the coils cU1 to cW2 corresponding to that connection portion b1C. This improves the ease of assembly of the reactor Rt.

[0044] In this embodiment, as shown in Fig. 6, in each phase, the first terminals e1 of the first coils cU1, cV1, and cW1 and the first terminals e1 of the second coils cU2, cV2, and cW2 are gathered directly above the first coils cU1, cV1, and cW1. As a result, in each of the three phases, the first bus bar b1 can be electrically connected to the first terminals e1 of the first coils cU1, cV1, and cW1 and the first terminals e1 of the second coils cU2, cV2, and cW2 directly above the first coils cU1, cV1, and cW1. As a result, the area of ​​the steel sheet material required to cut out the first bus bar b1 can be reduced to Figure 8 This allows for a smaller number of first bus bars compared to the first bus bars b1 of the comparative example shown in Fig. 1, which leads to an improvement in yield.

[0045] 2, in each phase, the second terminals e2 of the first coils cU1, cV1, and cW1 and the second terminals e2 of the second coils cU2, cV2, and cW2 are gathered directly above the second coils cU2, cV2, and cW2. As a result, in each of the three phases, the second bus bars bU, bV, and bW can be electrically connected to the second terminals e2 of the second coils cU2, cV2, and cW2 and the second terminals e2 of the first coils cU1, cV1, and cW1 directly above the second coils cU2, cV2, and cW2.

[0046] The first coils cU1, cV1, and cW1 and the second coils cU2, cV2, and cW2 shown in Fig. 1 all have the same shape, which allows the number of types of components of the reactor Rt to be reduced, thereby simplifying the reactor Rt configuration.

[0047] [Other embodiments] The above-described embodiment can be modified, for example, as follows. The reactor Rt shown in FIG. 1 may form part of a circuit other than the three-phase boost chopper Tc shown in FIG. 3. In the reactor Rt shown in FIG. 1, each of the three phases may include only the first coils cU1, cV1, and cW1, and may not include the second coils cU2, cV2, and cW2. In that case, the first bus bar b1 may have only three connection portions b1C, and each of the three second bus bars bU, bV, and bW may have only one connection portion b2C. [Explanation of symbols]

[0048] b1 First bus bar b1C First bus bar connection bU U-phase busbar (second busbar) bV V-phase busbar (second busbar) bW W-phase busbar (second busbar) cU1 U phase 1st coil (coil) (1st coil) cU2 U-phase second coil (coil) (second coil) cV1 V-phase 1st coil (coil) (1st coil) cV2 V-phase second coil (coil) (second coil) cW1 W-phase 1st coil (coil) (1st coil) cW2 W-phase 2nd coil (coil) (2nd coil) e1 First terminal of the coil e2 Second terminal of the coil Rt reactor

Claims

1. A reactor including: a coil provided for each phase arranged in a phase arrangement direction as a predetermined horizontal direction; and a first bus bar extending in the phase arrangement direction, For each phase, the coils include a first coil and a second coil arranged in a horizontal direction perpendicular to the phase arrangement direction and electrically connected in parallel to each other, Each of the coils includes a first terminal that is a part of a rectangular wire portion of the coil, and the surface perpendicular direction of the first terminal is the arrangement direction, In each of the phases, the first terminal of the first coil and the first terminal of the second coil are located directly above the first coil, the first bus bar includes a connection portion for each of the coils, and a surface-perpendicular direction of each of the connection portions is the arrangement direction; each of the connection portions of the first bus bar abuts against the first terminal of the coil corresponding to the connection portion in the arrangement direction, so that the first bus bar is electrically connected to the first terminal of the first coil and the first terminal of the second coil directly above each of the first coils. Reactor.

2. In each of the phases, the portion of the first coil on the side of the first terminal and the portion of the second coil on the side of the first terminal each extend upward and then extend horizontally toward directly above the first coil, so that the first terminal of the first coil and the first terminal of the second coil are located directly above the first coil. The reactor according to claim 1 .

3. a second bus bar for each of the phases; the coil includes a second terminal; In each of the phases, the second terminal of the first coil and the second terminal of the second coil are located directly above the second coil, In each of the phases, the second bus bar is electrically connected to the second terminal of the second coil and the second terminal of the first coil directly above the second coil. The reactor according to claim 1 or 2.

4. In each of the phases, the portion of the first coil on the second terminal side and the portion of the second coil on the second terminal side each extend upward and then extend horizontally toward directly above the second coil, so that the second terminal of the first coil and the second terminal of the second coil are located directly above the second coil. The reactor according to claim 3 .

5. Each of the first coils and each of the second coils have the same shape. The reactor according to claim 1 or 2.

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