JP5951933B2 - Core module, coil device, and manufacturing method of core module - Google Patents

Description

  The present invention relates to a core module in which a core and a bobbin are integrally formed, and a coil device including the core module.

  In a large capacity coil device (for example, a reactor) used in a drive system of a hybrid vehicle or an electric vehicle, a structure in which a bobbin wound with a coil is covered on a core is generally employed. Patent Document 1 discloses a reactor having a configuration in which a coil is directly wound around a core body in which a plurality of core blocks constituting a split core and a ceramic spacer are integrally resin-molded. That is, the core body disclosed in Patent Document 1 is obtained by integrally molding a core and a bobbin.

  By integrally molding the core and the bobbin as in the core body of Patent Document 1, the number of parts when assembling the coil device is reduced, so that the efficiency of the assembly work is improved.

JP 2009-26952 A

  The core body of Patent Document 1 can be mass-produced by, for example, injection molding (insert molding). However, since it takes a long time to accurately place a large number of members in the mold, the cost of the injection molding is increased accordingly. In addition, a large mold is required to mold the entire core at once, and the production cost of the mold is enormous.

  A ring-type core module for a coil device according to an embodiment of the present invention has a pair of U-type core pieces and a plurality of I-type core pieces, each formed of a magnetic material. In the ring-type core module, a plurality of I-type core pieces are arranged between opposing U-shaped end portions in a state where a pair of U-type core pieces are arranged to face each other, and a plurality of I-type cores are disposed inside a pair of linear coils This is a configuration in which a fragment is inserted. Each of the pair of U-shaped core pieces and the plurality of I-shaped core pieces has an insulating coating formed by insert molding, and is bonded to each other via a non-magnetic gap member between the core pieces to form a ring shape. The

  Each core unit constituting the ring-type core module having the above-described configuration does not include a plurality of core pieces, so that it is easy to set up insert molding and can be manufactured efficiently and at low cost. Moreover, since each core unit is a small unit having only one core piece, each core module can be molded with a small mold, and the manufacturing cost of the mold can be reduced.

  The insulation coating may not be formed on the gap surface facing the gap member of the U-type and I-type core pieces.

  By attaching the gap member directly to the gap surface, the thickness of the gap can be accurately formed.

  Each of the U-type and I-type core pieces has two gap surfaces, and the insulating coating around the two gap surfaces is formed with a bonding structure for bonding to each of the other core pieces. A first joint structure may be formed around one of the two, and a second joint structure having a shape that can be joined to the first joint structure may be formed around the other.

  A structure in which a common joint structure is formed in each of the U-type core piece and the I-type core piece facilitates the design of the joint structure and the manufacture of the mold.

  The first joint structure has a pair of projecting portions that are opposed to each other with the outer peripheral portion of the insulating coating projecting in a direction perpendicular to the gap surface and sandwiching the gap surface, and the second joint structure is formed on the outer peripheral portion of the insulating coating. When the first and second joining structures are abutted with each other, the pair of recesses are sandwiched between the pair of protrusions, and the first and second portions are formed. The joint structure may be configured so as to be positioned in the opposing direction of the protrusion.

  With the above-described configuration, it is possible to accurately position the core pieces without performing a precise positioning operation simply by abutting and inserting the joint surfaces of the core pieces.

  The first and second joining structures each have a plurality of gap member support portions that project in a direction perpendicular to the gap surface and sandwich the plate-like gap member from the side surface, and the plurality of gap member support portions are vertically or horizontally And may be arranged asymmetrically.

  With the above configuration, even when the gap member support portions having the same shape are provided in the same arrangement in the first and second joint structures, the gap member support portions of the joint structures do not overlap each other. Therefore, the gap member support portion can be formed as thick as the gap member, and the gap member can be more reliably supported.

  The plurality of gap member support portions may be arranged point-symmetrically with respect to the center of the gap surface and asymmetrically in the vertical and horizontal directions.

  According to the said structure, since a gap member is clamped from both sides on both sides of a gravity center by the pair of gap member support part arrange | positioned point-symmetrically in each joining structure, it is supported more stably.

  The shape and arrangement of the plurality of gap member support portions may be the same in the first and second joining structures.

  By making the shape and arrangement of the gap member support portion common to each joint structure, the joint structure can be easily designed and the mold can be manufactured.

  The plurality of type I core fragments may have the same shape. Further, the pair of U-shaped core pieces may have the same shape.

  A plate-like sensor fixing member extending in the opposite direction from the bottom of the U-shape is further formed on the insulating coating of the U-shaped core piece, and the sensor fixing member is disposed between the pair of linear coils, You may form the space which can accommodate a rod-shaped sensor head between a pair of U-shaped core piece sensor fixing members.

  Since the types of constituent members (core pieces on which insulation coating is formed) of the ring-type core module are reduced, it is possible to efficiently manufacture the constituent members and reduce the inventory. In addition, core modules of various sizes can be produced simply by changing the number of I-shaped core fragments to be connected.

  In addition, a ring-type core module for a coil device according to another embodiment of the present invention has a pair of U-shaped core pieces each formed of a magnetic material, and the ring-type core module is a pair of U-shaped cores. The U-shaped end portions of the U-shaped core fragments are inserted to face each other inside the pair of linear coils in a state in which the fragments are opposed to each other, and each of the pair of U-shaped core fragments is insulated by insert molding. It is formed and bonded to each core piece via a non-magnetic gap member to form a ring shape.

  A coil device according to an embodiment of the present invention includes the core module and a pair of coils.

The core module manufacturing method according to the embodiment of the present invention includes a step of forming an insulating coating by insert molding on each of the pair of U-shaped core pieces and the plurality of I-shaped core pieces formed from a magnetic material, After the step of forming an insulating coating, the pair of U-shaped core pieces and the plurality of I-shaped core pieces are bonded to each other via a non-magnetic gap member between the core pieces to form a ring shape; including.

  In addition, a method for manufacturing a ring-type core module for a coil device having a pair of U-shaped core pieces according to an embodiment of the present invention includes a method of manufacturing each of the pair of U-shaped core pieces formed from a magnetic material by insert molding. A step of forming an insulating coating, and a step of forming a ring shape by bonding a pair of U-shaped core pieces through a non-magnetic gap member after the step of forming the insulating coating.

  Provided is a core module that can be manufactured at a low cost by integrally forming a core and a bobbin.

It is a perspective view of the reactor which concerns on embodiment of this invention. It is an exploded view of the reactor which concerns on embodiment of this invention. It is a top view of the reactor which concerns on embodiment of this invention. It is AA sectional drawing in FIG. It is BB sectional drawing in FIG. It is an exploded view of the reactor main body which concerns on embodiment of this invention. It is a front view of the U-shaped core unit which concerns on embodiment of this invention. It is a front view of an I type core unit concerning an embodiment of the present invention. It is CC sectional drawing in FIG. It is an exploded view (plan view) of a core. (A) Core 20a of this embodiment, (b) Core 20 'of another embodiment

  Hereinafter, a reactor 1 according to an embodiment of the present invention will be described with reference to the drawings. 1, 2 and 3 are a perspective view, an exploded view and a plan view of the reactor 1, respectively. 4 and 5 are respectively a cross-sectional view taken along line AA and a cross-sectional view taken along line BB in FIG. In the following description, the direction from the lower left side to the upper right side in FIG. 1 is the width direction (X axis direction), the direction from the lower right side to the upper left side is the depth direction (Y axis direction), and from the lower side to the upper side. The direction to go is defined as the height direction (Z-axis direction). The positive Z-axis direction is called the upper side, and the negative Z-axis direction is called the lower side. In addition, when using the reactor 1, you may arrange | position the reactor 1 toward what direction.

  As shown in FIGS. 1 and 2, the reactor 1 fixes a reactor main body 1 a, a heat radiating case 50, and a reactor main body 1 a (directly the core 20) composed of a coil 10 and a core 20 to the heat radiating case 50. A pair of core fixtures 30, the thermistor 40, and a terminal block 60 are provided. The reactor 1 of this embodiment employs a floating structure in which the reactor main body 1a is attached in the heat radiating case 50 without being in direct contact with the heat radiating case 50. That is, the core fixtures 30 attached to both ends of the reactor 1 in the X-axis direction support the reactor 1 accommodated in the heat dissipation case 50 in a floating state without directly contacting the heat dissipation case 50. The core fixing tool 30 is a metal fitting formed from a stainless steel plate, and is formed into a shape that reduces vibrations generated by the reactor main body 1a (particularly vibrations of high-frequency components that cause noise) and makes it difficult to transmit to the case. ing. Therefore, with this support structure, the vibration generated in the reactor body 1a is not damped and is not directly transmitted to the heat radiating case 50, but is mitigated by the core fixture 30, so that noise and vibration transmitted from the reactor 1 to the outside are not generated. It is greatly reduced. In addition, since the impact received by the heat radiating case 50 from the outside is alleviated by the core fixture 30, the reactor 1 has excellent impact resistance. In addition, after the reactor main body 1a is fixed to the heat radiating case 50, the gap in the heat radiating case 50 is filled with a filler (illustrated) which is a relatively soft resin having a good thermal conductivity. Thereby, the required heat dissipation performance is ensured while preventing vibration propagation from the reactor body 1a to the heat dissipation case 50. Further, the temperature of the operating reactor main body 1 a is detected by the thermistor 40.

  FIG. 6 is an exploded view of the reactor main body 1a. The core 20 is a ring core in which two U-shaped core units 220 and four I-shaped core units 240 are bonded together via a gap member 20g to form a substantially O-shape. FIG. 7 is a front view of the U-type core unit 220, and FIG. 8 is a front view of the I-type core unit 240 (also serving as a rear view). In addition, the U-type core unit 220 and the I-type core unit 240 are obtained by coating divided core pieces each formed of a magnetic material with an insulating resin, as will be described later. Further, various structures for positioning and supporting the coil are formed on the covering of each core unit. That is, the coating of each core unit has a bobbin function, and the core 20 is formed by integrally forming a core body made of a magnetic material and a bobbin made of an insulating resin.

  The gap member 20g is a non-magnetic plate having a predetermined thickness. The gap member 20g of the present embodiment is made of alumina, but may be made of other types of ceramics or resins.

  The U-shaped core unit 220 is obtained by coating a U-shaped core piece 20u, which is a dust core formed in one U shape, with a resin by injection molding (insert molding). The U-shaped core piece 20u is covered with resin only on the side surface through which the magnetic path does not pass, and the gap surfaces 20a and 20b facing the gap member 20g are exposed without being covered with resin. In this embodiment, polyphenylene sulfide (PPS) having excellent heat resistance is used as the coating resin for the U-type core unit 220, but other types of resins having insulating properties may be used. Further, a silicon steel plate or ferrite may be used for the U-shaped core piece 20u.

  At each end of the U-shape of the U-shaped core unit 220, a bonding structure for bonding to the I-shaped core unit 240 is formed in the covering resin portion surrounding the exposed gap surfaces 20a and 20b. In addition, the junction structure is formed in different shapes around the gap surface 20a and the gap surface 20b. In the outer peripheral part of the coating surrounding the gap surface 20a arranged on the right side in FIG. 7, plate-like projecting parts 224a, b, c, d projecting in the X-axis direction are formed. In addition, a gap member support 226 that protrudes in the X-axis direction is formed between the upper left end of the gap surface 20a in FIG. 7 and the protrusion 224d. In addition, a gap member support portion 226 protruding in the X-axis direction is also formed between the lower right end of the gap surface 20a and the protruding portion 224b. Furthermore, substantially L-shaped gap member support portions 227 protrude in the X-axis direction in the vicinity of the upper right end portion and the left lower end portion of the gap surface 20a. The dimension in the X-axis direction (height protruding from the gap surface 20a) of the gap member support portions 226 and 227 is set slightly thinner than the thickness of the gap member 20g. The gap member 20g is disposed in a space surrounded by the gap member support portions 226 and 227, and is sandwiched from the side surfaces by the gap member support portions 226 and 227 and positioned. In the following description, the end surface shape of the core unit in which the protruding portions 224a, b, c, d and the gap member support portions 226, 227 are formed on the coating resin surrounding the gap surface in this way is referred to as “convex core end surface shape”. "

  On the other hand, recesses 225a, b, c, d having shapes respectively corresponding to the protrusions 224a, b, c, d are formed on the outer peripheral portion of the covering surrounding the gap surface 20b arranged on the left side in FIG. Yes. Further, a gap member support 226 protruding in the X-axis direction is formed between the upper left end of the gap surface 20b and the recess 225b, and the gap member support 226 protruding in the X-axis direction also between the lower right end and the recess 225d. Is formed. Furthermore, a substantially L-shaped gap member support portion 227 protrudes in the X-axis direction in the vicinity of the upper right end portion and the left lower end portion of the gap surface 20b. In the following description, the end surface shape of the core unit in which the recesses 225a, b, c, d and the gap member support portions 226, 227 are formed in the coating resin surrounding the gap surface 20b as described above is referred to as “concave core end surface shape”. Call it. Detailed functions of the protrusions 224a, b, c, d, the recesses 225a, b, c, d and the gap member support portions 226, 227 will be described later.

  As shown in FIG. 2, a pair of brackets 221 having a female screw for attaching the core fixing tool 30 is formed on the outer side surface 220 m (side surface not having a joining structure) in the X-axis direction of the U-shaped core unit 220. ing. Also, as shown in FIGS. 6 and 7, plate-like flange portions 222 and 223 are formed to protrude substantially vertically from the lower surface of the U-shaped core unit 220 and from both side surfaces perpendicular to the Y-axis direction, respectively. Yes. Two coil support portions 222a are formed at the lower end of the flange portion 222 so as to protrude inward in the X-axis direction (side on which the coil 10 is disposed) from directly below the center of each gap surface 20a, 20b. Further, a flat plate-shaped sensor support portion 228 extending in parallel with the ZX plane is formed so as to protrude substantially perpendicularly from the center portion in the Y-axis direction of the inner surface 220n in the X-axis direction of the U-shaped core unit 220. Further, a sensor lead winding part 229 for winding a lead 44 of the thermistor 40 described later is formed so as to protrude from the upper surface of the U-shaped core unit 220. A slit 229 s extending in the Y-axis direction for inserting the lead 44 is formed in the upper part of the sensor lead winding part 229. Further, a narrowed portion 229n that makes it difficult for the lead 44 to come off the slit 229s is formed at the entrance of the slit 229s. Detailed functions of the flange portion 222, the coil support portion 222a, and the sensor lead winding portion 229 will be described later.

  The I-type core unit 240 is obtained by coating an I-type core piece 20i, which is a dust core formed in one rectangular parallelepiped shape, with a resin by insert molding. In the I-type core piece 20i, only the peripheral surface through which the magnetic path does not pass is covered with resin, and the gap surfaces 20c and 20d facing the gap member 20g are exposed without being covered with resin. The covering portion of the I-type core unit 240 is formed of the same resin as the covering portion of the U-type core unit 220.

  The gap surfaces 20c and 20d are formed on the end surfaces in the X-axis direction of the I-type core unit 240, respectively. As shown in FIGS. 6 and 8, the coating around one gap surface 20 c of the I-type core unit 240 is formed in the same convex core end surface shape as the circumference of the gap surface 20 a of the U-type core unit 220 described above. Has been. Specifically, the outer peripheral portion of the coating surrounding the gap surface 20c protrudes in the X-axis direction to form plate-like protrusions 244a, b, c, and d. Further, a gap member support portion 246 protruding in the X-axis direction is formed between the upper left end of the gap surface 20c in FIG. 8 and the protruding portion 244d. In addition, a gap member support portion 246 that protrudes in the X-axis direction is also formed between the lower right end of the gap surface 20c and the protrusion portion 244b. Furthermore, a substantially L-shaped gap member support portion 247 protrudes in the X-axis direction in the vicinity of the upper right end portion and the left lower end portion of the gap surface 20c.

  In addition, two coil support protrusions 248 are formed on the upper surface of the I-type core unit 240 at the center in the Y-axis direction to prevent bending due to the weight of the coil 10.

  On the other hand, the resin coating around the other gap surface 20 d of the I-type core unit 240 is formed in the same concave core end surface shape as the periphery of the gap surface 20 b of the U-type core unit 220 described above. Specifically, recesses 245a, b, c, and d having shapes corresponding to the protrusions 244a, b, c, and d are formed on the outer peripheral surface of the coating surrounding the gap surface 20d. Further, a gap member support 226 protruding in the X-axis direction is formed between the upper left end of the gap surface 20d and the recess 245b, and a gap member support 226 protruding in the X-axis direction is formed between the lower right end and the recess 245d. Is formed. Furthermore, a substantially L-shaped gap member support portion 227 protrudes in the X-axis direction in the vicinity of the upper right end portion and the left lower end portion of the gap surface 20d.

  In the present embodiment, the shape of the protrusions 244a to 244d of the I-type core unit 240 and the arrangement with respect to the gap surface 20c are the same as the shape of the protrusions 224a to 224d of the U-type core unit 220 and the arrangement with respect to the gap surface 20a. It is. Similarly, the shape of the recesses 245a to 245d of the I-type core unit 240 and the arrangement with respect to the gap surface 20d are the same as the shape of the recesses 225a to d of the U-type core unit 220 and the arrangement with respect to the gap surface 20b. The shape of the gap member support portions 226 and 227 and the arrangement with respect to the gap surface are common to the gap surfaces 20 a and 20 b of the U-type core unit 220 and the gap surfaces 20 c and 20 d of the I-type core unit 240.

  Convex core end surface shapes formed around the gap surface 20a of the U-type core unit 220 and the gap surface 20c of the I-type core unit 240, the gap surface 20b of the U-type core unit 220, and the gap surface of the I-type core unit 240. The shape of the concave core end surface formed around 20d is configured such that the gap member 20g is sandwiched between the gap surfaces while positioning the gap surfaces and the interposed gap member 20g in the YZ plane direction. ing. For example, when the gap surface 20a of the U-type core unit 220 and the gap surface 20d of the I-type core unit 240 are abutted via the gap member 20g, protrusions 224a, b, c, formed around the gap surface 20a, d is accommodated in recesses 245a, b, c, d formed around the gap surface 20d, respectively. As a result, the gap surface 20a and the gap surface 20d are positioned in the Y direction and the Z direction.

In addition, the gap member support portions 226 and 246, 227 and 247 have the same shape, and the arrangement on each joint surface is also the same. Further, the arrangement of the gap member support portions on the joint surfaces is asymmetric in FIGS. 7 and 8. For example, in the joint surface on the right side of FIG. 7, the symmetrical positions 226 ′ and 227 ′ of the gap member support portions 226 and 227 with respect to the symmetry plane C ₁ (the symmetry surfaces of the protrusions 224b and 224d that are in plane symmetry with each other). The gap member support portion is not formed. With this configuration, when the convex core end face shape and the concave core end face shape are brought into contact with each other, there is no interference between the gap member support portions having the respective end face shapes. That is, when the gap surface 20d of the I-type core unit 240 is abutted against the gap surface 20a of the U-type core unit 220, the gap member support portions 226 and 227 formed around the gap surface 20d are arranged around the gap surface 20a. The gap member support portions 226 and 227 around the gap surface 20a and the gap surface 20d do not overlap each other. For this reason, each gap member support part 226,227 can be formed thickly to the same extent as the gap member 20g. When assembling the core 20, for example, the gap member support portions 226 and 227 are formed thick to sandwich the gap member 20g between the gap member support portions 226 and 227 of the U-type core unit 220 (or I-type core unit 240). As a result, the gap member 20g is securely held, and the assembling work becomes easy. Further, since the gap member support portions 226 and 227 are formed slightly thinner than the gap member 20g, the close contact with the gap surfaces 20a and 20d of the gap member 20g is not hindered. Further, since the peripheral edge of the gap member 20g is sandwiched by the gap member support portions 226 and 227 from both sides in the Y-axis direction and the Z-axis direction, the gap member 20g has the Y-axis direction and the gap surfaces 20a and 20d. Positioning in the Z-axis direction is performed.

Further, as shown in FIG. 7, around the gap surface 20a, a pair of gap member support 226 and 227 are formed at positions of point symmetry with respect to the center point C ₀ of the gap surface 20a . With this arrangement, the gap member 20g is stably held by the gap member support portions 226 and 227 from both sides across the center of gravity. Further, the gap member support portions 226 and 227 formed around the gap surface 20a are also symmetrical with respect to the symmetry plane C ₂ shown in FIG. 7 (the symmetry plane of the protrusions 224a and 224c that are in plane symmetry with each other). Arranged asymmetrically. With this configuration, even when the pair of gap member support portions are arranged at point-symmetrical positions with respect to the center point C ₀ , when the convex core end surface shape and the concave core end surface shape are abutted with each other, the gap of each end surface shape Interference between member support portions does not occur.

  The coil 10 has a structure in which two linear coil portions 10a and 10b formed of a flat enameled wire are arranged in parallel and the winding starts (the lower left end in FIG. 6) are connected to each other. The two linear portions of the core 20 formed by connecting two I-type core units 240 are accommodated in the hollow portions of the linear coil portions 10a and 10b.

  The heat dissipation case 50 is formed with a pedestal 52 having a screw hole 52f for attaching the core fixture 30 and a screw hole 54 for attaching the terminal block 60. In addition, a recess 56 is formed on the inner bottom surface of the heat radiating case 50 at a position facing the coil support portion 222a in order to prevent contact with the coil support portion 222a protruding toward the inner bottom surface side.

  Next, a procedure for assembling the reactor main body 1a will be described. First, an adhesive is applied to the gap surfaces 20a and 20b of one U-shaped core unit 220, and the gap member 20g is placed on each of them. Specifically, each gap member 20g is inserted into a space surrounded by each gap member support portion 226 and 227. Next, an adhesive is applied to the exposed surface of the gap member 20g placed on the gap surface 20a, and the gap surface 20d of the first I-type core unit 240 is overlaid thereon. In addition, an adhesive is applied to the exposed surface of the gap member 20g placed on the gap surface 20b, and the gap surface 20c of the second I-type core unit 240 is overlaid thereon.

  Next, an adhesive is applied to the gap surface 20c of the first I-type core unit 240 and the gap surface 20d of the second I-type core unit 240, and the gap member 20g is placed on each of them. Then, an adhesive is applied to the exposed surface of the gap member 20g placed on the gap surface 20c, and the gap surface 20d of the third I-type core unit 240 is overlaid thereon. In addition, an adhesive is applied to the exposed surface of the gap member 20g placed on the gap surface 20d, and the gap surface 20c of the fourth I-type core unit 240 is overlaid thereon. Further, an adhesive is applied to the gap surface 20c of the third I-type core unit 240 and the gap surface 20d of the fourth I-type core unit 240, and the gap member 20g is placed on each of them.

  At this stage, the core 20 has two parallel straight portions formed by stacking two I-type core units 240 on the gap surfaces 20a and 20b of the U-type core unit 220, and is elongated in the X-axis direction. It is formed in a U shape. Next, the two straight portions of the core 20 are inserted into the hollow portions of the two straight coil portions 10 a and 10 b of the coil 10. Then, an adhesive is applied to the exposed surfaces of the gap member 20g placed on the gap surface 20c of the third I-type core unit 240 and the gap surface 20d of the fourth I-type core unit 240, respectively. The U-shaped core unit 220 is overlapped with the gap surfaces 20b and 20a, and the adhesive is cured in a state where a predetermined compressive load (adhesive load) is applied to the assembled core 20 from both sides in the X-axis direction. The adhesive load is appropriately set so that the adhesive layer thickness is within a predetermined range.

  In the reactor main body 1a assembled in this way, the coil 10 is sandwiched between the flange portions 222 and 223 of the two U-shaped core units 220 at both ends in the X-axis direction and positioned with respect to the core 20 in the X-axis direction ( Figure 2).

  Further, the lower ends of the linear coil portions 10a and 10b of the coil 10 are supported from below by the coil support portions 222a extending from the lower ends of the flange portions 222 on the lower surfaces at both ends in the X-axis direction, and on the lower surfaces contacting the coil support portions 222a. The core 20 is positioned in the Z-axis direction (and with respect to the inner bottom surface of the heat dissipation case 50 to which the core 20 is fixed). With this configuration, the heat dissipation performance of the reactor 1 is dramatically improved. This effect will now be described in detail.

  As shown in FIG. 5, the reactor 1 according to the embodiment of the present invention has a floating structure that is supported so that the reactor main body 1 a does not come into contact with the heat radiating case 50. Most of the heat generated in the core 20 during operation is transmitted to the heat radiating case 50 via the filler filled in the gap between the coil 10 and the heat radiating case 50 and is radiated to the outside. Resin with relatively good thermal conductivity is used for the filler, but the gap filled with the filler is the place where the heat transfer rate is the slowest in the heat dissipation path, and the thickness of the filler layer Determines the heat dissipation performance of the reactor 1. Therefore, in order to improve the heat dissipation performance of the reactor 1, it is necessary to set the dimension of the gap between the coil 10 and the heat dissipation case 50 as small as possible. The set value of the gap G between the coil 10 and the heat radiating case 50 is determined by the dimensional accuracy, assembly accuracy, fluidity of the filler, displacement of the core 20 due to vibration during operation and external impact. It is determined by parameters such as quantity. Among these parameters, the dimensional accuracy of the coil 10 formed by bending with low processing accuracy is a main factor for increasing the set value of the gap G between the coil 10 and the heat radiating case 50.

  In order to minimize the error of the gap G caused by the coil 10 in the floating structure in which the coil 10 floats from the heat radiating case 50 as in the present embodiment, the positioning error of the lower surface of the coil 10 with respect to the inner bottom surface of the case 50 Must be minimized. Further, since the width dimension of the coil 10 (the dimension in the height direction in FIG. 5) varies greatly, for example, the coil 10 is supported at the upper part (that is, the coil 10 is positioned with reference to the upper part of the coil 10). The lower surface of the coil 10 can be positioned with higher accuracy with respect to the inner bottom surface of the heat radiating case 50 by supporting the coil 10 at the lower portion (that is, positioning with the lower portion of the coil 20 as a reference). Therefore, since the coil 10 is positioned with respect to the heat radiating case 50 on the lower surface by the configuration in which the lower surface of the coil 10 is supported from below by the coil support portion 222a as in the present embodiment, the coil 10 with respect to the inner bottom surface of the heat radiating case 50 is. The positioning accuracy of the lower surface of the sheet becomes high, and the value of the gap G can be set small. In the configuration of this embodiment, for example, a seat surface that supports the upper inner peripheral surface of the coil 10 such as the coil support protrusion 248 from below is provided on the upper surface of the core 20, and the coil 10 is supported and positioned only by this seat surface. Compared with the structure to perform, the positioning error (standard deviation) in the Z-axis direction of the lower surface of the coil 10 with respect to the heat dissipation case 50 is reduced by about 50%.

  The coil support protrusion 248 of the present embodiment is an auxiliary configuration for preventing a decrease in positioning accuracy due to the deflection of the coil 10. For example, when a large deflection occurs in the coil due to an impact or the like, The upper inner peripheral surface is supported from below and contact between the coil and the heat radiating case 50 is prevented. When the deflection of the coil 10 is not large, the coil 10 is not supported by the coil support protrusion 248 but is supported only by the coil support portion 222a.

  Next, the fixing structure of the thermistor 40 will be described. 9 is a cross-sectional view taken along the line CC in FIG. A sensor support portion 228 that protrudes inward in the X-axis direction from each U-shaped core unit 220 is disposed at the approximate center in the Y-axis direction of the reactor 1. The sensor support portion 228 is a flat resin portion that extends in parallel with the ZX plane, and is disposed in the gap between the two linear coil portions 10 a and 10 b of the coil 10. The sensor support portion 228 further protrudes in the X-axis direction from the rectangular support plate 228a that protrudes in the X-axis direction from the main body portion of the U-shaped core unit 220, and from the upper and lower ends at the tip end in the X-axis direction of the support plate 228a. It has a protrusion 228b and a wall 228c. Further, the pair of sensor support portions 228 are formed symmetrically in FIG. 9, and the protruding portion 228 b and the wall portion 228 c are formed to face each other in the X-axis direction. The sensor head of the thermistor 40 is arranged in the arrangement space S surrounded by the pair of support plates 228a, the protruding portion 228b, and the wall portion 228c.

  As shown in FIG. 9, the thermistor 40 includes a sheath part (sensor head) 42 in which a thermistor element (not shown) is accommodated by a metal tube, and a pair of leads 44 extending from one end (base end part 42 b) of the sheath part 42. It has. The lead 44 is rigid enough to support the weight of the sheath portion 42 and is folded back in a J shape at the base (near the base end portion 42b of the sheath portion 42). The sheath portion 42 of the thermistor 40 is arranged in the arrangement space S surrounded by the sensor support portions 228 of the two U-shaped core units 220. Further, the lead 44 is drawn out of the arrangement space through the protruding portion 228b, is entangled with the sensor lead winding portion 229 formed on the upper surface of the U-shaped core unit 220, and is further drawn out of the reactor 1. And connected to a temperature measuring instrument (not shown).

  The thermistor 40 is attached to the reactor body 1a after the reactor body 1a is assembled. The thermistor 40 is mounted in a state in which the lead 44 is bent in a J shape at the base in advance. The mounting operation is performed by operating the lead 44 having a certain rigidity. First, the lead 44 is pushed in, and the sheath portion 42 is introduced into the arrangement space S from the base end portion 42b side through the protruding portion 228b. Next, the distal end of the sheath part 42 is moved upward along the end surface of one of the support plates 228a (left side in FIG. 9), and the distal end part 42a of the sheath part 42 is brought into contact with the protruding part 228b. Further, when the lead 44 is pulled while applying tension, the sheath portion 42 is rotated around the tip portion 42a of the sheath portion 42, and the U-shaped bent portion 44a of the lead 44 is the other (right side in FIG. 9) support plate 228a. It abuts on the end face of. When the U-shaped bent portion 44a comes into contact with the other support plate 228a, the rotation of the sheath portion 42 is prevented and stops. When the lead 44 is wound around the sensor lead winding part 229 so as not to loosen in this state, the sheath part 42 is fixed at a predetermined position in the arrangement space S shown in FIG.

  The distance between the tips of the pair of protrusions 228b (opening width W1) is wide enough to allow the sheath part 42 and the lead 44 folded back in a J shape to pass through. Specifically, the opening width W <b> 1 is formed wider than the width F between the sheath portion 42 and the outer side surface of the lead 44 in the portion where the lead 44 is folded back along the sheath portion 42. As a result, the sheath portion 42 and the folded lead 44 can be introduced into the arrangement space S through the space between the protruding portions 228b. Further, the opening width W <b> 1 is narrower than the length L from the distal end 42 a of the sheath portion 42 to the U-shaped bent portion 44 a of the lead 44. Thereby, the sheath part 42 which once entered the arrangement space S cannot easily escape from the arrangement space S.

  Further, the pair of wall portions 228c each extend long in the X-axis direction, and the distance between the tips (gap width W2) is narrow enough to prevent the sheath portion 42 from passing therethrough. Specifically, the gap width W <b> 2 is formed narrower than the overall width F of the sheath portion 42 and the folded lead 44. This prevents the thermistor 40 from being brought into contact with the heat radiating case 50 and conducting.

  Further, the distance (diagonal depth D) from the tip of the protrusion 228 b to the diagonal in the arrangement space S is longer than the length L from the tip 42 a of the sheath portion 42 to the U-shaped bent portion 44 a of the lead 44. It has become. Accordingly, the sheath portion 42 and the portion of the lead 44 that is folded back along the sheath portion 42 can be accommodated in the arrangement space S.

  The distance between the pair of support plates 228a (arrangement space width W3) is shorter than the length L from the distal end 42a of the sheath portion 42 to the U-shaped bent portion 44a of the lead 44. When the lead 44 is pulled in a state where the distal end 42a of the sheath portion 42 is in contact with the end surfaces of one of the support plates 228a and the protruding portion 228b, both of which form a corner portion, the arrangement space is arranged with the distal end 42a of the sheath portion 42 as an axis. In S, the sheath part 42 rotates. However, when the arrangement space width W3 is shorter than the length L, the U-shaped bent portion 44a of the lead 44 comes into contact with the other support plate 228a to prevent further rotation, and the thermistor 40 is placed in the arrangement space S. Fixed.

  The above is the description of the exemplary embodiments of the present invention. Embodiments of the present invention are not limited to those described above, and can be arbitrarily changed within the scope of the technical idea expressed by the description of the scope of claims.

  The core 20 of the above embodiment has a configuration in which a plurality of I-type core units 240 are arranged between a pair of U-type core units 220 as shown in FIG. However, in another embodiment, as shown in FIG. 10A, the ring core may be configured by only a pair of U-shaped core units 220 '. Note that the U-shaped core unit 220 differs from the U-shaped core unit 220 of the above-described embodiment only in dimensions, for example. In this case, the ring core 20 'is formed by abutting and fixing the end faces of the pair of U-shaped core units 220' through a pair of gap members 20g. The U-shaped core piece 20u 'of the magnetic material included in the U-shaped core unit 220' has both ends of the U-shaped core piece 20u in the above embodiment extended in the X-axis direction to form a straight line portion. The straight portions of the U-shaped core unit 220 ′ (portions where the straight portions of the U-shaped core piece 20 u ′ are covered) are respectively disposed in the straight coil portions 10 a and 10 b of the coil 10.

  Moreover, although embodiment described above is an example which applied this invention to the reactor, this invention can also be applied to another kind of coil apparatus (for example, transformer).

DESCRIPTION OF SYMBOLS 1 Reactor 10 Coil 12, 14 Lead part 20 Core 20g Gap member 220 U type core unit 20u U type core piece 221 Bracket 222 Flange part (coil positioning part)
222a Coil support part 223 Flange part (coil positioning part)
224a-d Projection 225a-d Recess 226 Gap member support 227 Gap member support 228 Sensor support 228a Support plate 228b Projection 228c Wall 240 I-type core unit 20i I-type core fragment 244a-d Projection 245a-d Concave portion 246 Gap member support portion 247 Gap member support portion 30 Core fixture 44 Lead 44a U-shaped bent portion 50 Case 52 Base 52f Screw hole 54 Screw hole 60 Terminal block 62, 64 Bus bar 72 Bolt

Claims (12)

A ring-type core module for a coil device,
Each having a pair of U-shaped core fragments and a plurality of I-shaped core fragments, each formed of a magnetic material;
In the ring-type core module, the plurality of I-type core pieces are arranged between opposing U-shaped end portions in a state where the pair of U-type core pieces are arranged to face each other, and the plurality of I-type core pieces are disposed inside a pair of linear coils The type I core fragment is inserted,
The pair of U-shaped core pieces and a plurality of I-shaped core pieces is coated with respective insulating coating, characterized in that it is I stuck case via a gap member of non-magnetic material between the core pieces Core module. 2. The core module according to claim 1, wherein the insulating coating is not formed on a gap surface facing the gap member of the U-shaped and I-shaped core pieces. Each of the U-type and I-type core pieces has two gap surfaces,
Each of the insulating coatings around the two gap surfaces is formed with a joining structure for joining with another core piece,
A first joining structure is formed around one of the two gap surfaces, and a second joining structure having a shape that can be joined to the first joining structure is formed around the other. The core module according to claim 2. The first bonding structure has a pair of projecting portions in which an outer peripheral portion of the insulating coating projects in a direction perpendicular to the gap surface and faces the gap surface.
The second bonding structure has a pair of recesses that are formed on the outer peripheral portion of the insulating coating and accommodate each of the pair of protrusions,
When the first and second joint structures are abutted, the pair of recesses are sandwiched between the pair of protrusions, and the first and second joint structures are positioned in the opposing direction of the protrusions. The core module according to claim 3, wherein the core module is characterized. The first and second joining structures each have a plurality of gap member support portions that protrude in a direction perpendicular to the gap surface and sandwich the plate-like gap member from the side surface,
5. The core module according to claim 3, wherein the plurality of gap member support portions are asymmetrically arranged vertically or horizontally.   The core module according to claim 5, wherein the plurality of gap member support portions are arranged point-symmetrically with respect to a center point of the gap surface and asymmetrical in the vertical and horizontal directions.   The core module according to claim 6, wherein the plurality of gap member support portions have the same shape and arrangement in the first and second joining structures.   The core module according to any one of claims 1 to 7, wherein the plurality of I-type core fragments have the same shape.   The core module according to claim 8, wherein the pair of U-shaped core pieces have the same shape. The insulating cover of the U-shaped core piece is further formed with a plate-shaped sensor fixing member extending in the opposite direction from the bottom of the U-shape,
The sensor fixing member is disposed between the pair of linear coils, and forms a space capable of accommodating a rod-shaped sensor head between the pair of linear coils and the sensor fixing member of the pair of U-shaped core pieces. The core module according to claim 9, wherein:   A coil device comprising the core module according to any one of claims 1 to 10 and the pair of coils. A method of manufacturing a ring-type core module for a coil device having a pair of U-type core pieces and a plurality of I-type core pieces,
In the ring-type core module, the plurality of I-type core pieces are arranged between opposing U-shaped end portions in a state where the pair of U-type core pieces are arranged to face each other, and the plurality of I-type core pieces are disposed inside a pair of linear coils. The type I core fragment is inserted,
Forming an insulating coating by insert molding on each of the pair of U-shaped core pieces and the plurality of I-shaped core pieces formed of a magnetic material;
After the step of forming the insulating coating, the pair of U-shaped core pieces and the plurality of I-shaped core pieces are bonded to each other via a non-magnetic gap member between the core pieces to form a ring shape. A method for manufacturing a core module, comprising:

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