Reactors, converters, and power conversion devices

Abstract

To provide a reactor that is compact and ensures sufficient electrical insulation from an attachment surface.SOLUTION: A reactor includes a coil having a winding portion, a magnetic core having an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion, and a spacer disposed between an end face of the winding portion and the outer core portion. The outer core portion has a first surface perpendicular to a first direction, the first direction being a direction intersecting an axis of the winding portion. The spacer extends along the first surface and includes a first overhang portion overlapping the first surface, and a first convex portion protruding toward the first direction. The first convex portion protrudes in the first direction beyond the outer core portion and the winding portion.SELECTED DRAWING: Figure 1

Description

Technical Field

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

Background Art

[0002] Patent Document 1 discloses a reactor including a coil having a winding portion and a magnetic core. In the reactor of Patent Document 1, a resin mold portion covering the magnetic core is formed, and a fixing portion is formed in the resin mold portion. The fixing portion is configured to fix the reactor to an attachment surface of an object on which the reactor is disposed. The resin mold portion ensures electrical insulation between the winding portion and the magnetic core and also ensures electrical insulation between the magnetic core and the object to be disposed. <0000​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​A magnetic core having an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion, A spacer is provided between the end face of the winding portion and the outer core portion, The outer core portion has a first surface perpendicular to the first direction, and the first direction is a direction that intersects the axis of the winding portion. The previous spacer is A first eaves portion that extends along the first surface and overlaps with the first surface, It comprises a first protrusion that projects toward the first direction, The first protrusion protrudes in the first direction more than the outer core portion and the winding portion. [Effects of the Invention]

[0007] The reactor of this disclosure is compact and has sufficient electrical insulation from the mounting surface. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a schematic perspective view of the reactor described in Embodiment 1, seen from an oblique angle above. [Figure 2] Figure 2 is a schematic perspective view of the reactor shown in Figure 1, viewed from a diagonal downward angle. [Figure 3] Figure 3 is a cross-sectional view taken along line III-III in Figure 1. [Figure 4] Figure 4 is a schematic perspective view of the spacer provided in the reactor shown in Figure 1. [Figure 5] Figure 5 is an explanatory diagram illustrating the creepage distance in the reactor described in Embodiment 1. [Figure 6] Figure 6 is a schematic diagram showing the arrangement of reactors in a case with an elongated space. [Figure 7] Figure 7 is a schematic diagram showing the power supply system of a hybrid vehicle. [Figure 8] Figure 8 is a circuit diagram showing an example of a power conversion device equipped with a converter.

Mode for Carrying Out the Invention

[0009] [Description of Embodiments of the Present Disclosure] First, embodiments of the present disclosure will be listed and described.

[0010] <1> The reactor according to the embodiment includes a coil having a winding portion, a magnetic core having an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion, and a spacer disposed between an end face of the winding portion and the outer core portion, and includes the outer core portion includes a first surface orthogonal to a first direction, and the first direction is a direction intersecting an axis of the winding portion, the spacer includes a first eaves portion extending along the first surface and overlapping the first surface, and a first convex portion protruding in the first direction, and the first convex portion protrudes in the first direction more than the outer core portion and the winding portion.

[0011] By arranging the reactor on the mounting surface so that the first convex portion of the reactor contacts the mounting surface, the reactor can be placed upright on the mounting surface. At that time, electrical insulation between the outer core portion of the magnetic core and the mounting surface is ensured by the first convex portion and the first eaves portion. Therefore, in the above reactor, Resin mold part is not required. A reactor having no Resin mold part is small and can be arranged in, for example, an elongated space. [[ID=:37]]

[0012] <2> In the reactor described in <1> above, the first surface includes a flat portion and a concave portion, the first eaves portion is disposed in the concave portion, the flat portion and a surface of the first eaves portion facing the first direction may be flush.

[0013] By positioning the first overhang portion in the recess, the thickness of the reactor in the first direction becomes thinner. Such reactors are easy to place, for example, in elongated spaces.

[0014] <3> the above <1> or <2> In the reactor described, The creepage distance from the first protrusion along the surface of the spacer to the outer core portion may be 4 mm or more.

[0015] If the creepage distance is 4 mm or more, sufficient electrical insulation is ensured between the outer core and the mounting surface.

[0016] <4> the above <1> from <3> In a reactor described in any of the following, The surface of the first eaves portion facing the first direction and the surface of the winding portion facing the first direction may be flush with each other.

[0017] the above <4> According to the configuration described, the winding portion can be made larger as long as it does not come into contact with the mounting surface. As a result, a sufficient magnetic path cross-sectional area can be secured for the inner core portion located inside the winding portion.

[0018] <5> the above <1> from <4> In a reactor described in any of the following, The inner core portion is made of a composite material in which soft magnetic powder is dispersed in a resin. The inner core portion may be in contact with the inner circumferential surface of the winding portion.

[0019] The above configuration <5> According to the configuration described, the inner core can be fabricated simply by filling the inside of the winding section with a composite material. Furthermore, the magnetic path cross-sectional area of ​​the inner core, which is located inside the winding section, can be increased.

[0020] <6> the above <5> In the reactor described, The outer core portion is made of the composite material, The inner core portion and the outer core portion may be a single integrated unit.

[0021] the above <6> According to the configuration described, the inner core and outer core can be manufactured at the same time. Therefore, the productivity of the reactor is improved.

[0022] <7> the above <1> from <6> In a reactor described in any of the following, The winding portion may have a flattened shape that is thinned in the first direction.

[0023] the above <7> According to the configuration described, when the reactor is placed on the mounting surface, the height of the reactor in the vertical direction of the mounting surface can be reduced. Such a reactor is easy to place, for example, in a long, narrow space.

[0024] <8> the above <1> from <7> In a reactor described in any of the following, The outer core portion has a second surface facing a second direction opposite to the first direction, The previous spacer is A second canopy portion that extends along the second surface and overlaps with the second surface, It comprises a second protrusion that protrudes toward the second direction, The second protrusion may protrude more than the outer core portion and the winding portion in the second direction.

[0025] the above <8> According to the configuration described, the reactor can be positioned to fit into a long, narrow space. The long, narrow space comprises a first mounting surface and a second mounting surface facing each other. In this case, the reactor is positioned such that the first and second protrusions are in contact with the first and second mounting surfaces, respectively. Electrical insulation between the first mounting surface and the outer core is ensured by the first protrusion and the first overhang, and electrical insulation between the second mounting surface and the outer core is ensured by the second protrusion and the second overhang.

[0026] <9> The converter in this disclosure is as described above. <1> from <8> It is equipped with a reactor as described in any of the following.

[0027] The reactor according to this embodiment is small and lightweight. Therefore, the converter equipped with the reactor according to this embodiment is also small and lightweight.

[0028] <10> The power conversion device of this disclosure is as described above. <9> It is equipped with the converter described.

[0029] The converter according to this embodiment is small and lightweight. Therefore, the power conversion device equipped with the converter according to this embodiment is also small and lightweight.

[0030] [Details of the embodiments of this disclosure] Embodiments of the reactors, converters, and power converters of this disclosure will be described below with reference to the drawings. The same reference numerals in the drawings indicate the same parts. However, the present invention is not limited to the configurations shown in the embodiments, but is intended to be limited to those shown in the claims, and all modifications within the meaning and scope of the claims are intended to be included.

[0031] <Embodiment 1> The reactor 1 of this example, shown in Figures 1 and 2, comprises a coil 2, a magnetic core 3, and spacers 4 and 5. One of the features of this example lies in the configuration of spacers 4 and 5. The details of the reactor 1 of this disclosure will be described below.

[0032] ≪Coil≫ Coil 2 has at least one winding section 21. Coil 2 in this example comprises one winding section 21. The winding section 21 is constructed by winding a wire spirally. Known windings can be used for the winding. The winding in this embodiment is a coated flat wire made of a conductor wire having an insulating coating. The conductor wire is, for example, made of copper flat wire. The insulating coating is, for example, made of enamel. The winding section 21 in this example is an edgewise coil made by winding a coated flat wire edgewise.

[0033] The winding portion 21 has a rectangular tube shape. That is, the end face shape of the winding portion 21 in this example is rectangular frame-shaped. The corners of the winding portion 21 in this example are rounded. The winding portion 21 in this example also has a flattened shape that is rectangular when viewed along the axis of the winding portion 21.

[0034] Here, the directions in reactor 1 are defined with respect to coil 2. First, the direction from the first end to the second end of winding section 21 along the axis of winding section 21 is the X1 direction. The direction from the first side surface to the second side surface of winding section 21 is the Y1 direction. The Y1 direction is perpendicular to the X1 direction. The first side surface and the second side surface are the surfaces that constitute the short side when viewing the flattened winding section 21 in the X1 direction. The direction perpendicular to the X1 and Y1 directions is the Z1 direction. The X2, Y2, and Z2 directions are the opposite directions of the X1, Y1, and Z1 directions, respectively.

[0035] The winding portion 21 in this example has a flattened shape that is thinner in the first direction. In this example, the first direction coincides with the Z1 direction, as will be described in the description of the outer core portion 32 later. When this flattened winding portion 21 is viewed in the X1 direction, if the length of the winding portion 21 along the Y1 direction is the width W of the winding portion 21, and the length of the winding portion 21 along the Z1 direction is the height H of the winding portion 21, then the ratio H / W of the width W to the height H of the winding portion 21 is, for example, 1 / 20 or more and less than 1. The ratio H / W may also be 1 / 15 or more and less than 1, or 1 / 10 or more and less than 1. A winding portion 21 having such a flattened shape is easy to place in an elongated space 90 as shown in Figure 6.

[0036] The ends 22 and 23 of the winding are drawn out from the winding section 21. In this example, both ends 22 and 23 are drawn out from the winding section 21 in the Y2 direction. The insulation coating is stripped off at ends 22 and 23, exposing the conductor wires. Terminal members (not shown) are connected to the exposed conductor wires. Ends 22 and 23 are located within the height H range of the winding section 21. Therefore, ends 22 and 23 do not increase the dimensions of the winding section 21 in the Z1 direction.

[0037] Unlike this example, if there are, for example, two winding sections 21, the two winding sections 21 may each be connected to an independent power source, or they may be connected to a single power source.

[0038] Magnetic Core The magnetic core 3 is a magnetic material in which a closed magnetic circuit is formed inside. The magnetic core 3 is a compacted powder body or a molded body of a composite material. The magnetic core 3 may be constructed by combining a core piece made of compacted powder and a core piece made of a molded composite material, or by covering the outer circumference of a core piece made of compacted powder with a composite material.

[0039] The compacted body is formed by pressure molding raw material powder containing soft magnetic powder. The soft magnetic powder is, for example, pure iron or an iron alloy. The iron alloy is, for example, an Fe (iron)-Si (silicon) alloy or an Fe-Ni (nickel) alloy. The raw material powder may also contain a lubricant. The soft magnetic powder content in the compacted body is, for example, more than 80% by volume, and more specifically 85% or more, when the entire compacted body is considered as 100% by volume.

[0040] A molded composite material is produced by filling a mold with a mixture of soft magnetic powder and unsolidified resin, and then solidifying the resin. In a molded composite material, the soft magnetic powder is dispersed in the resin. Examples of resins include polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin such as nylon 6 or nylon 66, polybutylene terephthalate (PBT) resin, and acrylonitrile butadiene styrene (ABS) resin. The resin may also be BMC (Bulk molding compound) made by mixing calcium carbonate or glass fibers with unsaturated polyester, millable silicone rubber, or millable urethane rubber. The content of soft magnetic powder in the composite material is, for example, 30% to 80% by volume when the total volume of the composite material is considered as 100% by volume. The content of soft magnetic powder in the composite material may further be 50% or more by volume, 60% or more by volume, or 70% or more by volume.

[0041] As shown in Figure 3, the magnetic core 3 comprises an inner core portion 31 and an outer core portion 32. In Figure 3, the boundary between the inner core portion 31 and the outer core portion 32 is indicated by a dashed line. The inner core portion 31 is located inside the winding portion 21 of the coil 2 and is aligned with the axis of the winding portion 21. The number of inner core portions 31 is the same as the number of winding portions 21. In this example, there is one winding portion 21, so there is also one inner core portion 31. In this example, both ends of the portion of the magnetic core 3 that aligns with the axis of the winding portion 21 protrude from the end face of the winding portion 21. These protruding portions are also part of the inner core portion 31.

[0042] The outer core portion 32 is the part of the magnetic core 3 that is located outside the winding portion 21. 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. As shown in Figures 1 and 2, the outer core portion 32 in this example is composed of an end core portion 321 facing the end face in the X1 direction of the winding portion 21, an end core portion 322 facing the end face in the X2 direction of the winding portion 21, and a side core portion 323 facing the side surface in the Y1 direction of the winding portion 21. This outer core portion 32 is rectangular C-shaped when viewed in the Z2 direction. Unlike this example, there may be two side core portions. In that case, the outer core portion 32 includes a side core portion facing the side surface in the Y2 direction of the winding portion 21 in addition to the side core portion 323. Such an outer core portion 32 is rectangular annular when viewed in the Z2 direction. In addition, if the number of winding sections 21 and the number of inner core sections 31 are two, the outer core section 32 is composed of, for example, an end core section that connects the ends of the two inner core sections 31, 31 in the X1 direction, and an end core section that connects the ends of the two inner core sections 31, 31 in the X2 direction.

[0043] The outer core portion 32 comprises a first surface 33 (Figure 1) facing a first direction and a second surface 34 (Figure 2) facing a second direction. The first surface 33 is a surface parallel to the surface of the winding portion 21 that has the largest area when viewed from a direction along any axis of a three-dimensional Cartesian coordinate system with the axis of the winding portion 21 as the X-axis. The first direction is the direction that intersects the axis of the winding portion 21. For example, the first direction is the direction perpendicular to the axis of the winding portion 21 and toward the mounting surface to which the reactor 1 is attached. In this example, the Z1 direction is the first direction. The second direction is the opposite direction of the first direction. In this example, the Z2 direction is the second direction. Unlike this example, the Z2 direction may be the first direction, or the Y1 direction may be the first direction, or the Y2 direction may be the first direction.

[0044] As shown in Figure 1, the first surface 33 of this example is composed of surfaces facing the Z1 direction in the two end core portions 321 and 322, and a surface facing the Z1 direction in the side core portion 323. In other words, the first surface 33 of this example is C-shaped when viewed in the Z2 direction. As shown in Figure 3, this first surface 33 comprises a flat portion 33s, a recess 33c formed at the position of the end core portion 321, and a recess 33c formed at the position of the end core portion 322. The majority of the first surface 33 is the flat portion 33s. The flat portion 33s is parallel to the XY plane. Of the two recesses 33c, the recess 33c positioned in the X1 direction is formed in the portion of the end core portion 321 closer to the winding portion 21. On the other hand, the recess 33c positioned in the X2 direction is formed in the portion of the end core portion 322 closer to the winding portion 21. The two recesses 33c, 33c are recessed in the Z2 direction, i.e., the second direction, compared to the flat portion 33s. The first overhang portions 40, 50 of the spacers 4, 5, which will be described later, are positioned in these recesses 33c, 33c.

[0045] As shown in Figure 2, the second surface 34 of this example is composed of surfaces facing the Z2 direction in the two end core portions 321 and 322, and a surface facing the Z2 direction in the side core portion 323. In other words, the second surface 34 of this example is C-shaped when viewed in the Z1 direction. As shown in Figure 3, this second surface 34 comprises a flat portion 34s, a recess 34c formed at the position of the end core portion 321, and a recess 34c formed at the position of the end core portion 322. The majority of the second surface 34 is the flat portion 34s. The flat portion 34s is parallel to the XY plane. Of the two recesses 34c, the recess 34c positioned in the X1 direction is formed in the end core portion 321 near the winding portion 21. On the other hand, the recess 34c positioned in the X2 direction is formed in the end core portion 322 near the winding portion 21. The two recesses 34c, 34c are recessed portions in the Z1 direction, i.e., the first direction, compared to the flat portion 34s. The second overhang portions 42 and 52 of the spacers 4 and 5, which will be described later, are positioned in these recesses 34c, 34c.

[0046] In this example, the magnetic core 3 is formed from a molded composite material. More specifically, the inner core portion 31 and the outer core portion 32 are a single piece made of the composite material. Such a magnetic core 3 is manufactured by filling a mold in which the coil 2 is placed with the composite material.

[0047] The composite material filled inside the winding portion 21 constitutes the inner core portion 31. This inner core portion 31 is in contact with the inner circumferential surface 21s of the winding portion 21. In this case, no other member is placed between the inner circumferential surface 21s of the winding portion 21 and the inner core portion 31. Therefore, a large magnetic path cross-sectional area of ​​the inner core portion 31 within the winding portion 21 is secured. However, if there is a defect such as a pinhole in a part of the insulating coating of the winding that constitutes the winding portion 21, the conductor wire of the winding and the inner core portion 31 may come into partial contact. However, even if the conductor wire and the inner core portion 31 come into local contact, the characteristics of the reactor 1 will only be slightly reduced, and the contact will not pose a major problem.

[0048] The composite material filled outside the winding portion 21 within the mold constitutes the outer core portion 32. The outer circumference of the outer core portion 32 is not molded with resin or the like and is exposed to the outside of the reactor 1. In other words, the outer surface of the outer core portion 32 constitutes part of the outer surface of the reactor 1. If this bare outer core portion 32 is in direct contact with the mounting surface to which the reactor 1 is attached, a conductive path will be formed from the outer core portion 32 to the mounting surface. If current leaks from the conductor wire of the winding portion 21 to the inner core portion 31, and the outer core portion 32 is in contact with the mounting surface, the current may ground fault and the reactor 1 may stop working. In this example, spacers 4 and 5, which will be described later, ensure electrical insulation between the outer core portion 32 and the mounting surface.

[0049] Spacer In this example, reactor 1 is equipped with two spacers 4 and 5. Spacer 4 is positioned between the end face of the winding portion 21 and the end core portion 321 of the outer core portion 32. Spacer 5 is positioned between the end face of the winding portion 21 and the end core portion 322 of the outer core portion 32. These spacers 4 and 5 ensure electrical insulation between the winding portion 21 and the outer core portion 32.

[0050] Spacers 4 and 5 are made of an electrically insulating material. Examples of such materials include PPS resin, PTFE resin, LCP, PA resin, PBT resin, and ABS resin. Alternatively, the material of spacers 4 and 5 may be a thermosetting resin such as an unsaturated polyester resin, epoxy resin, urethane resin, or silicone resin. These resins may also contain ceramic fillers. The ceramic fillers are, for example, non-magnetic powders such as alumina or silica.

[0051] As shown in the schematic perspective view of Figure 4, the spacer 4 comprises a through hole 4h, a first overhang portion 40, a first protrusion 41, a second overhang portion 42, and a second protrusion 43 (see Figures 2 and 3). The through hole 4h serves as a passage for the composite material when the magnetic core 3 is formed from the composite material. The inner core portion 31 and the outer core portion 32 are connected at the location of the through hole 4h.

[0052] As shown in Figure 3, the first canopy portion 40 extends along the first surface 33 of the outer core portion 32 and overlaps with the first surface 33. The first canopy portion 40 is intended to ensure a creepage distance between the mounting surface to which the reactor 1 is attached and the outer core portion 32, as will be described later.

[0053] The first visor portion 40 is positioned in the recess 33c of the first surface 33. The first visor portion 40 is fitted into the recess 33c. The surface of the first visor portion 40 facing the first direction is flush with the flat portion 33s of the first surface 33. The first direction coincides with the Z1 direction. By positioning the first visor portion 40 in the recess 33c, the thickness of the reactor 1 along the Z1 direction is reduced.

[0054] The surface of the first eaves portion 40 facing the first direction and the surface of the winding portion 21 facing the first direction are flush. In this case, the winding portion 21 can be made larger as long as it does not come into contact with the mounting surface. Therefore, the magnetic path cross-sectional area of ​​the inner core portion 31 located inside the winding portion 21 is sufficiently secured.

[0055] The first protrusion 41 projects in a first direction. This first protrusion 41 protrudes further in the first direction than the outer core portion 32 and the winding portion 21. This first protrusion 41 contacts the mounting surface of the reactor 1, preventing the winding portion 21 and the outer core portion 32 of the coil 2 from contacting the mounting surface.

[0056] The height of the first protrusion 41 in the first direction is, for example, 0.01 mm or more and 2 mm or less. If the height is 0.01 mm or more, it is easy to secure an insulating distance between the mounting surface and the winding portion 21 and the outer core portion 32. If the height is 2 mm or less, the dimensions of the reactor 1 in the first direction will not become too large. The height may also be, for example, 0.05 mm or more and 1 mm or less, or 0.1 mm or more and 0.5 mm or less.

[0057] As shown in Figures 1 and 4, the number of first protrusions 41 may be singular or plural. In this example, there are two first protrusions 41. Of course, there may be three or more first protrusions 41.

[0058] The shape of the first protrusion 41 is not particularly limited. In this example, the first protrusion 41 is a truncated square pyramid shape that is elongated in the Y1 direction. Unlike this example, the first protrusion 41 may be a truncated cone shape or a truncated pyramid shape other than a square.

[0059] The first protrusion 41 has an end face 41e and a side wall surface 41s, as shown in Figure 5. The end face 41e is the surface that contacts the mounting surface. The side wall surface 41s is the surface that connects the end face 41e to the surface of the spacer 4 excluding the first protrusion 41 that faces the first direction. The creepage distance from the outer peripheral edge of the end face 41e along the surface of the spacer 4 to the outer core portion 32 is, for example, 4 mm or more. In this example, the creepage distance is the shortest distance from the outer peripheral edge of the end face 41e along the side wall surface 41s and the surface of the first eaves portion 40 to the edge of the first eaves portion 40 in the X1 direction, as shown by the bent double-ended arrows in Figure 5. If the creepage distance is 4 mm or more, sufficient electrical insulation between the outer core portion 32 and the mounting surface is ensured. Depending on the degree of contamination of the surrounding environment or the operating voltage, the creepage distance may be, for example, 5 mm or more, 7 mm or more, or 10 mm or more. The longer the creepage distance, the easier it is to ensure electrical insulation between the outer core portion 32 and the mounting surface.

[0060] The second visor portion 42 and the second protrusion portion 43 shown in Figures 2 and 3 have the same function as the first visor portion 40 and the first protrusion portion 41, differing only in their formation position and orientation. Here, only the formation position and orientation of the second visor portion 42 and the second protrusion portion 43 will be explained.

[0061] As shown in Figure 3, the second visor portion 42 extends along the second surface 34 of the outer core portion 32 and overlaps with the second surface 34. The second visor portion 42 is positioned in the recess 34c of the second surface 34. The second visor portion 42 is fitted into the recess 34c. The surface of the second visor portion 42 facing the second direction is flush with the flat portion 34s of the second surface 34. Also, the surface of the second visor portion 42 facing the second direction is flush with the surface of the winding portion 21 facing the second direction. The second direction coincides with the Z2 direction.

[0062] The second protrusion 43 projects in a second direction. This second protrusion 43 protrudes more in the second direction than the outer core portion 32 and the winding portion 21.

[0063] The height of the second protrusion 43 in the second direction is, for example, 0.01 mm or more and 2 mm or less. The height may also be 0.05 mm or more and 1 mm or less, or 0.1 mm or more and 0.5 mm or less.

[0064] As shown in Figure 2, the number of second protrusions 43 may be singular or plural. In this example, there are two second protrusions 43. The shape of the second protrusions 43 is not particularly limited. In this example, the second protrusions 43 are elongated in the Y1 direction and have a truncated square pyramidal shape.

[0065] The creepage distance from the second protrusion 43 to the outer core 32 may be, for example, 4 mm or more, or depending on the degree of contamination of the surrounding environment or the operating voltage, it may be 5 mm or more, 7 mm or more, or 10 mm or more. The creepage distance of the second protrusion 43 is the same as that of the first protrusion 41. The explanation of the creepage distance of the second protrusion 43 is the same as the explanation of the first protrusion 41 in Figure 5, but with "first protrusion 41" replaced by "second protrusion 43".

[0066] Spacer 5 comprises a through hole 5h, a first overhang 50, a first protrusion 51, a second overhang 52, and a second protrusion 53 (see Figures 2 and 3), as shown in the schematic perspective view of Figure 4. The description of spacer 5 can be obtained by replacing "through hole 4h," "first overhang 40," "first protrusion 41," "second overhang 42," and "second protrusion 43" in the description of spacer 4 with "through hole 5h," "first overhang 50," "first protrusion 51," "second overhang 52," and "second protrusion 53," respectively.

[0067] The spacer 5 further includes a side portion 54. The side portion 54 extends in the X1 direction from the Y1 direction end of the spacer 5. As shown in Figure 1, this side portion 54 is positioned between the winding portion 21 and the side core portion 323. The surface of the side portion 54 facing the winding portion 21 is an arcuate surface that follows the outer shape of the winding portion 21. Of the arcuate surface of the side portion 54, the end in the X1 direction functions as a second engaging portion 55 that engages with the first engaging portion 45 of the spacer 4. The first engaging portion 45 is an arcuate bulge formed at the Y1 direction end of the spacer 4. The first engaging portion 45 and the second engaging portion 55 are joined together, for example, with an adhesive.

[0068] The side portion 54 has the function of determining the relative positions of spacer 4 and spacer 5. In addition, the side portion 54 has the function of preventing the composite material constituting the side core portion 323 from coming into contact with the winding portion 21 when the magnetic core 3 is formed from the composite material.

[0069] ≪Reactor placement≫ Referring to Figure 6, an example of the arrangement of the reactor 1 in Embodiment 1 will be explained. In Figure 6, the first protrusions 41, 51 and the second protrusions 43, 53 of the reactor 1 are shown larger than their actual dimensions for clarity.

[0070] As shown in Figure 6, the reactor 1 is located in case 9. In this example, case 9 has an elongated space 90 sandwiched between two plate members. The elongated space 90 includes mounting surfaces 91 and 92 that face each other.

[0071] The first protrusion 41 of spacer 4 and the first protrusion 51 of spacer 5 are in contact with the mounting surface 91. The first protrusions 41 and 51 hold the winding portion 21 and the outer core portion 32 at a position away from the mounting surface 91. In the vicinity of the first protrusion 41, the first protrusion 41 and the first overhang portion 40 ensure a sufficient creepage distance from the mounting surface 91 to the end core portion 321, and in the vicinity of the first protrusion 51, the first protrusion 51 and the first overhang portion 50 ensure a sufficient creepage distance from the mounting surface 91 to the end core portion 322. Therefore, ground faults between the current flowing through the winding portion 21 of the reactor 1 and the mounting surface 91 are suppressed.

[0072] The second protrusion 43 of spacer 4 and the second protrusion 53 of spacer 5 are in contact with the mounting surface 92. The second protrusions 43 and 53 hold the winding portion 21 and the outer core portion 32 at a distance from the mounting surface 92. In the vicinity of the second protrusion 43, the second protrusion 43 and the second overhang portion 42 ensure a sufficient creepage distance from the mounting surface 92 to the end core portion 321, and in the vicinity of the second protrusion 53, the second protrusion 53 and the second overhang portion 52 ensure a sufficient creepage distance from the mounting surface 92 to the end core portion 322. Therefore, ground faults between the current flowing through the winding portion 21 of the reactor 1 and the mounting surface 92 are suppressed.

[0073] In this example, in the direction toward the mounting surface 91, none of the outer circumferential surfaces of the winding portion 21, the outer circumferential surfaces of the outer core portion 32, or the end portion 23 of the winding portion 21 protrude from the first eaves portions 40 and 50. Also, in the direction toward the mounting surface 92, none of the outer circumferential surfaces of the winding portion 21, the outer circumferential surfaces of the outer core portion 32, or the end portion 22 of the winding portion 21 protrude from the second eaves portions 42 and 52. Therefore, it is easy to position the reactor 1 so that it fits into the narrow space 90.

[0074] Although not shown in the diagram, insulating members may be placed between the winding portion 21 and the mounting surface 91, and between the winding portion 21 and the mounting surface 92. The insulating members have the function of releasing the heat from the reactor 1 to the case 9. The insulating members are, for example, insulating sheets or insulating grease.

[0075] <Embodiment 2> <<Converters / Power Conversion Devices>> The reactor 1 according to the above embodiment can be used for applications that satisfy the following energizing conditions. For example, the energizing conditions are that the maximum DC current is approximately 100A to 1000A, the average voltage is approximately 100V to 1000V, and the operating frequency is approximately 5kHz to 100kHz. The reactor 1 according to the embodiment is typically used as a component of a converter attached to a vehicle such as an electric vehicle or a hybrid vehicle, or as a component of a power conversion device equipped with such a converter.

[0076] A vehicle 1200, such as a hybrid or electric vehicle, includes a main battery 1210, a power converter 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 propulsion, as shown in Figure 7. The motor 1220 is typically a three-phase AC motor, which drives the wheels 1250 during driving and functions as a generator during regenerative braking. In the case of a hybrid vehicle, the vehicle 1200 is equipped with an engine 1300 in addition to the motor 1220. In Figure 7, the charging point of the vehicle 1200 is an inlet, but it may also be equipped with a plug.

[0077] The power converter 1100 includes a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 that performs mutual conversion between DC and AC. In this example, the converter 1110 boosts the input voltage of the main battery 1210, which is approximately 200V to 300V, to approximately 400V to 700V when the vehicle 1200 is running, and supplies power to the inverter 1120. During regeneration, the converter 1110 steps down the input voltage output from the motor 1220 via the inverter 1120 to a DC voltage suitable for the main battery 1210, thereby charging the main battery 1210. The input voltage is a DC voltage. When the vehicle 1200 is running, the inverter 1120 converts the DC voltage boosted by the converter 1110 into a predetermined AC voltage and supplies power to the motor 1220. During regeneration, it converts the AC output from the motor 1220 into DC voltage and outputs it to the converter 1110.

[0078] As shown in Figure 8, the converter 1110 comprises a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor 1115, and converts the input voltage by repeatedly switching ON / OFF. In this case, the input voltage conversion is step-up or step-down. Power devices such as field-effect transistors and insulated-gate bipolar transistors are used as switching elements 1111. The reactor 1115 utilizes the property of a coil that tries to oppose changes in the current that is about to flow through the circuit, and has the function of smoothing the change when the current tries to increase or decrease due to the switching operation. The reactor 1115 is provided as reactor 1 according to the embodiment.

[0079] Vehicle 1200 includes, in addition to converter 1110, a power supply device 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 which serves as a power source for auxiliary equipment 1240, and which converts the high voltage of the main battery 1210 to low voltage. Converter 1110 typically performs DC-DC conversion, while the power supply device converter 1150 and the auxiliary power converter 1160 perform AC-DC conversion. Some power supply device converters 1150 also perform DC-DC conversion. The reactors of the power supply device converter 1150 and the auxiliary power converter 1160 have a configuration similar to reactor 1, etc., according to the embodiment, and reactors with appropriately changed size and shape can be used. Furthermore, reactor 1, etc., according to the embodiment can also be used for converters that convert input power, such as converters that only perform boosting or converters that only perform step-down. [Explanation of symbols]

[0080] 1 Reactor 2 coils 21. Turning section 21s Inner surface 22,23 End 3 Magnetic core 31 Inner core section 32 Outer core section 33 Front page 33c recess 33s flat part 34 Second side 34c recess 34s flat part 321, 322 End core section 323 Side core section 4.5 Spacer 4h,5h through hole 40,50 First eave 41, 51 First protrusion 42,52 Second eave part 43, 53 Second convex part 45 First engaging part 54 Side section 55 Second engaging part 41e End face 41s Side wall 9 cases 90 space 91,92 Mounting surface 1100 Power converter 1110 converter 1111 Switching elements 1112 Drive Circuit 1115 Reactor 1120 Inverter 1150 Converter for power supply device 1160 Auxiliary Power Converter 1200 vehicles 1210 Main Battery 1220 Motor 1230 Sub-battery 1240 Auxiliary equipment 1250 wheels 1300 engine

Claims

1. A coil having a winding section, A magnetic core having an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion, A spacer is provided between the end face of the winding portion and the outer core portion, The outer core portion has a first surface perpendicular to the first direction, and the first direction is a direction that intersects the axis of the winding portion. The previous spacer is A first eaves portion that extends along the first surface and overlaps with the first surface, It comprises a first protrusion that projects toward the first direction, The first protrusion protrudes in the first direction more than the outer core portion and the winding portion. Reactor.

2. The first surface comprises a flat portion and a recessed portion. The first canopy portion is positioned in the recess, The reactor according to claim 1, wherein the planar portion and the surface of the first eaves portion facing the first direction are flush with each other.

3. The reactor according to claim 1 or claim 2, wherein the creepage distance from the first protrusion along the surface of the spacer to the outer core portion is 4 mm or more.

4. The reactor according to claim 1 or claim 2, wherein the surface of the first eaves portion facing the first direction and the surface of the winding portion facing the first direction are flush with each other.

5. The inner core portion is made of a composite material in which soft magnetic powder is dispersed in a resin. The reactor according to claim 1 or claim 2, wherein the inner core portion is in contact with the inner circumferential surface of the winding portion.

6. The outer core portion is made of the composite material, The reactor according to claim 5, wherein the inner core portion and the outer core portion are a single integrated unit.

7. The reactor according to claim 1 or claim 2, wherein the winding portion has a flattened shape that is thinned in the first direction.

8. The outer core portion has a second surface facing a second direction opposite to the first direction, The previous spacer is A second canopy portion that extends along the second surface and overlaps with the second surface, It comprises a second protrusion that protrudes toward the second direction, The reactor according to claim 1 or claim 2, wherein the second protrusion protrudes in the second direction more than the outer core portion and the winding portion.

9. A reactor comprising the reactor according to claim 1 or claim 2, converter.

10. A converter comprising the converter described in claim 9, Power converter.

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