JP7793366B2 - reactor - Google Patents

Description

The present invention relates to a reactor.

A reactor primarily consists of a coil and a core. When current is passed through the coil, it generates magnetic flux according to the number of turns. Hereinafter, the coil that functions as an inductive reactance by generating magnetic flux when current is passed through it from the outside is referred to as the main coil. The core forms a closed magnetic circuit that passes the magnetic flux generated by the coil with a magnetic permeability higher than that of a vacuum. This reactor is an electromagnetic component that converts electrical energy into magnetic energy and stores and releases it.

Such reactors are used in a wide variety of applications. Typical reactors include boost reactors, series reactors, parallel reactors, current-limiting reactors, starting reactors, shunt reactors, neutral reactors, and arc-suppression reactors.

Boost reactors are incorporated into onboard boost circuits, such as those found in the drive systems of hybrid and electric vehicles. Series reactors are connected in series to motor circuits to limit current during short circuits. Parallel reactors stabilize current sharing between parallel circuits. Current-limiting reactors limit current during short circuits and are connected to them. Starting reactors are connected in series to motor circuits to protect the machine and limit starting current. Shunt reactors are connected in parallel to transmission lines to compensate for leading reactive power and suppress abnormal voltages. Neutral reactors are connected between the neutral point and the ground to limit the ground fault current that flows in the event of a ground fault in the power system. Arc-suppression reactors automatically extinguish the arc that occurs when a single-phase ground fault occurs in a three-phase power system.

In such reactors, an auxiliary winding may be provided to detect the reactor's state. The auxiliary winding receives the magnetic flux generated by the main coil and passes a current corresponding to the magnetic flux. By detecting the current value of this auxiliary winding, it can be used, for example, as a sensor to measure the magnetic flux generated by the reactor.

Patent No. 5267802

In recent years, progress in miniaturization of circuits and integration of electrical components has led to a demand for smaller reactors. A reactor consists of a coil attached to a core. To form a closed magnetic circuit, the core has a leg on which the coil is attached, other legs parallel to this leg, and a yoke that sandwiches the legs from both sides to form a closed ring shape. To make reactors smaller, the spacing between the legs is becoming narrower. Furthermore, the core is coated with insulating resin to insulate it from the coil. Therefore, the distance between the resin-coated legs is becoming even narrower.

The auxiliary winding is wound around the legs, pulled out, and then secured to the resin with adhesive tape or similar. As reactors become smaller, the task of precisely securing the auxiliary winding in the desired position with adhesive tape in such a narrow space is becoming more difficult, and there is a risk that the auxiliary winding may not be able to be properly installed without bending.

The present invention was proposed to solve the above problems, and its purpose is to provide a reactor in which an auxiliary winding is attached with high precision.

To achieve the above objective, a reactor according to an embodiment of the present invention comprises a main coil through which current flows from the outside, a core containing a magnetic body and to which the main coil is attached, a core coating resin that coats the core and is interposed between the core and the main coil, an auxiliary winding having an annular portion wound with one or more turns and into which magnetic flux from the main coil enters to generate current, and an insertion portion that extends from the core coating resin and into which the auxiliary winding is inserted to support the auxiliary winding.

The insertion portion may have a pair of opposing clamping walls spaced apart, and the annular portion of the auxiliary winding may be clamped between the pair of clamping walls.

One of the pair of sandwiching walls may be a partition wall separating the auxiliary winding and the main coil.

The insertion portions may be provided at two opposing locations across the annular portion of the auxiliary winding.

The auxiliary winding may have lead wires drawn out in parallel in the same direction from both ends of the annular portion, and the core coating resin may have a support wall that extends perpendicularly or obliquely to the annular portion and supports a curved area of the annular portion of the auxiliary winding that is 180 degrees opposite to the lead wires.

The auxiliary winding may have lead wires drawn out in parallel in the same direction from the annular portion, and the core coating resin may extend facing the annular portion of the auxiliary winding and have an abutment wall facing a curved area of the annular portion that is 180 degrees opposite to the lead wire, with the abutment wall facing the curved area on the lead wire side.

The core coating resin may have an L-shaped portion including the support wall, the L-shaped portion extending toward the annular portion of the auxiliary winding, an abutment wall facing a curved area of the annular portion that is 180 degrees opposite the lead wire, and the support wall extending and bending from the abutment wall, the abutment wall facing the curved area on the lead wire side, and the support wall extending and bending from the abutment wall toward the lead wire.

According to the present invention, the auxiliary winding is attached with high precision, resulting in a high-quality reactor.

FIG. 2 is a perspective view showing the main configuration of a reactor. FIG. FIG. 2 is a perspective view showing the entire configuration of the reactor. FIG. 2 is an exploded view of the core coating resin. FIG. 10 is a plan view of the short-leg resin portion as viewed from a direction perpendicular to the longitudinal direction of the yoke housing portion, the main coil insertion portion, and the connecting leg housing portion. FIG. 10 is a side view of the short-leg resin portion as viewed along the length direction of the yoke housing portion and in a direction perpendicular to the length direction of the main coil insertion portion and the connecting leg housing portion. FIG. 10 is a front view of the short-leg resin portion as viewed from a direction perpendicular to the longitudinal direction of the yoke housing portion and along the longitudinal direction of the main coil insertion portion and the connecting leg housing portion. FIG. FIG. 2 is an enlarged view showing the vicinity of the boundary between the main coil and the auxiliary winding.

The reactor according to an embodiment of the present invention will be described below with reference to the drawings. In each drawing, thickness, dimensions, positional relationships, ratios, shapes, etc. may be exaggerated for ease of understanding, but the present invention is not limited to such exaggeration.

Figure 1 is a perspective view showing the main configuration of a reactor of this embodiment. Reactor 1 is an electromagnetic component that converts electrical energy into magnetic energy and stores and releases it. Reactor 1 includes a main coil 2, a core 3, and an auxiliary winding 4. The main coil 2 and auxiliary winding 4 are attached to the core 3. For example, reactor 1 has three main coils 2 and three auxiliary windings 4 for one core 3.

The main coil 2 is an inductor that generates magnetic flux when current flows from the circuit in which the reactor 1 is incorporated, introducing inductive reactance into the circuit. The main coil 2 is a cylindrically wound body of conductive wire with an insulating coating such as enamel, and is formed by winding it in a spiral shape while shifting the winding position for each turn along the winding axis. The conductive wire of the main coil 2 is, for example, a rectangular wire, and is a spiral edgewise coil formed by winding the conductive wire so that the wide surface of the conductive wire extends in a direction perpendicular to the winding axis of the main coil 2. A flatwise coil, for example, can also be used as the main coil 2.

Lead wires 21 are drawn out from the beginning and end of the main coil 2. The lead wires 21 are connected to bus bars (not shown). Bus bars are connecting conductors for connecting to other devices in the circuit, and are long plates with conductors such as copper drawn out. Each lead wire 21 is connected to each bus bar by welding or other means. By connecting the terminals of other devices in the circuit to these bus bars, current can be supplied to the main coil 2 from outside.

To detect the state of the reactor 1, the auxiliary winding 4 receives the magnetic flux generated by the main coil 2 and passing through the core 3, generating an electromotive force corresponding to the magnetic flux and passing a current through an external device connected to the auxiliary winding 4, such as a magnetic sensor. The auxiliary winding 4 is a wound body in which conductive wire is wound approximately 360 degrees for one or more turns, with lead wires 41 at the beginning and end of the winding extending side by side. The auxiliary winding 4 is a round wire with an insulating coating such as enamel coating. The auxiliary windings 4 are arranged in one-to-one correspondence with the main coils 2, and are arranged near the flux-exiting end face of the corresponding main coil 2 to obtain magnetic flux that is less affected by magnetic flux leakage.

The core 3 contains a magnetic material and forms a closed magnetic circuit through which the magnetic flux generated by the main coil 2 passes with a magnetic permeability higher than that of a vacuum. Examples of magnetic materials include powder magnetic cores, ferrite cores, metal composite cores, and laminated steel plates. Powder magnetic cores are annealed compacts made by compressing magnetic powder. Magnetic powders are primarily iron-based, and examples include pure iron powder, iron-based permalloy (Fe-Ni alloy), Si-containing iron alloy (Fe-Si alloy), sendust alloy (Fe-Si-Al alloy), amorphous alloy, nanocrystalline alloy powder, and mixtures of two or more of these powders. Metal composite cores are made by mixing and molding magnetic powder and resin.

Figure 2 is a perspective view of the core 3, with some of the main coils 2 omitted for ease of explanation. The core 3 is a vertical lattice-shaped closed magnetic circuit equipped with a yoke portion 31, fitting legs 32, and connecting legs 33. The yoke portion 31 extends perpendicular to the winding axes of the main coil 2 and auxiliary winding 4, and has a length sufficient to encompass the entire main coil 2. The core 3 is equipped with a pair of yoke portions 31. The pair of yoke portions 31 sandwich the entire main coil 2 from both end faces perpendicular to the winding axis of the main coil 2.

The main coil 2 and auxiliary winding 4 are fitted into the fitting leg portions 32. The fitting leg portions 32 extend between the yoke portions 31 at intervals equal to the number of pairs of main coils 2 and auxiliary windings 4. These fitting leg portions 32 are hollow within the main core 3 and consist of a protrusion 32a and a discontinuous area 32b. The protrusion 32a extends from each yoke portion 31 and is made of the same type of magnetic material molded integrally with the yoke portion 31. The auxiliary winding 4 is hung on the protrusion 32a, which extends into the vicinity of the entrance to the annular surface of the main coil 2. The discontinuous area 32b is between the pair of protrusions 32a; in other words, the fitting leg portions 32 are discontinuous between the protrusions 32a. The connecting legs 33 extend on both sides of the fitting leg portions 32 and connect the pair of yoke portions 31.

However, the fitting leg portion 32 is not limited to this and may extend continuously between the yoke portions 31 without interruption. Furthermore, the fitting leg portion 32 may bridge between the yoke portions 31 and have a magnetic gap that prevents a decrease in inductance. The magnetic gap may be made of a non-magnetic material, ceramic, non-metal, resin, carbon fiber, or a composite material of two or more of these, gap paper, or an air gap.

Figure 3 is a perspective view showing the entire configuration of the reactor 1. The core 3 is coated with core coating resin 5, and after being coated with core coating resin 5, the main coil 2 and auxiliary winding 4 are attached to the core 34. The core coating resin 5 protects the core 3 from mechanical shock and also covers at least the areas where the main coil 2 and auxiliary winding 4 are close to the core 3, insulating the core 3 from the main coil 2 and auxiliary winding 4.

The core coating resin 5 has an auxiliary winding stopper 55 extending from the lattice-like surface 52a, which locks the lead wire 41 drawn from the attached auxiliary winding 4 to prevent it from coming loose. The lattice-like surface 52a is parallel to the plane including the yoke portion 31, the fitting leg portion 32, and the connecting leg portion 33, and appears lattice-like when the core coating resin 5 is viewed from a direction perpendicular to this lattice-like surface 52a. The auxiliary winding stopper 55 extends in a hook-like shape, reducing the diameter of the coating layer of the auxiliary winding 4 and fitting it in.

The core coating resin 5 may be made of, for example, epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Terephthalate), or a composite of these. The core coating resin 5 is insulating and heat-resistant. A thermally conductive filler may be mixed into the core coating resin 5.

The reactor 1 also includes a terminal block (not shown) for securing the busbar and fastening the busbar to the terminals of an external device. The reactor 1 also includes a case (not shown) that houses the reactor body, which consists of a core 3 covered with a core coating resin 5, and a main coil 2 and auxiliary winding 4 fitted into the core 3. The case is made of a lightweight metal with high thermal conductivity, such as an aluminum alloy, and has heat dissipation properties. The case has a roughly box-like shape with an open top and a closed bottom.

The gap between the reactor body and the case may be filled with a solidified filler. A relatively soft, highly thermally conductive resin is suitable for the filler, in order to ensure the heat dissipation performance of the main coil 2 and core 3 and to reduce vibration transmission from the main coil 2 and core 3 to the case. It is also preferable for the filler to have insulating properties. Examples of such fillers include silicone resin, urethane resin, epoxy resin, and acrylic resin.

Figure 4 is an exploded view of the core coating resin 5. As shown in Figure 4, the core coating resin 5 is composed of a short-leg resin portion 51 and a long-leg resin portion 56. The short-leg resin portion 51 has a yoke housing portion 52 that covers the yoke portion 31. A main coil insertion portion 53 extends from the yoke housing portion 52, covering the fitting leg portion 32 and into which the main coil 2 fits. Furthermore, a connection leg housing portion 54 extends from the yoke housing portion 52, covering the connection leg portion 33.

The long-leg resin part 56 also has a yoke housing part 57 that covers the yoke part 31. A main coil insertion part 58 extends from the yoke housing part 57, covering the fitting leg part 32 and into which the main coil 2 fits. Furthermore, a connection leg housing part 59 extends from the yoke housing part 57, covering the connection leg part 33. In the short-leg resin part 51 and the long-leg resin part 56, the main coil insertion part 53 and connection leg housing part 54 of the short-leg resin part 51 are shorter than the main coil insertion part 58 and connection leg housing part 59 of the long-leg resin part 56.

In the short-leg resin portion 51, main coil insertion portions 53 and connection leg insertion portions 54 are alternately arranged along the extension direction of the yoke insertion portion 52. Furthermore, in the long-leg resin portion 56, main coil insertion portions 58 and connection leg insertion portions 59 are alternately arranged along the extension direction of the yoke insertion portion 57. The short-leg resin portion 51 covers one yoke portion 31 from which the protrusion 32a protrudes with the yoke insertion portion 52 and main coil insertion portion 53. The long-leg resin portion 56 covers the other yoke portion 31 from which the protrusion 32a protrudes with the yoke insertion portion 57 and main coil insertion portion 58. Furthermore, the long-leg resin portion 56 covers the connection leg 33 with the connection leg insertion portion 59. The connection leg 33 is exposed from the tip of the connection leg insertion portion 59 of the long-leg resin portion 56 by the same length as the connection leg insertion portion 54 of the short-leg resin portion 51.

The main coil 2 is then attached to the main coil insertion portion 58 of the long-leg resin portion 56. The connection leg 33 exposed from the connection leg housing 59 is inserted into the connection leg housing 54. The main coil insertion portion 53 of the short-leg resin portion 51 is then aligned with the main coil insertion portion 58 of the long-leg resin portion 56, and the connection leg housing 54 of the short-leg resin portion 51 is aligned with the connection leg housing 59 of the long-leg resin portion 56, and the core 3 is assembled into a closed loop. The auxiliary winding 4 is attached to the main coil insertion portion 53 so that it passes between the main coil insertion portion 53 of the short-leg resin portion 51 and one of the adjacent connection leg housings 54, makes a circuit around the main coil insertion portion 53, and is pulled out from between this main coil insertion portion 53 and the other adjacent connection leg housing 54.

Figures 5 to 8 show the installation of the auxiliary winding 4 relative to the short-leg resin portion 51. Figure 5 is a perspective view of the short-leg resin portion 51. Figure 6 is a plan view seen from a direction perpendicular to the longitudinal direction of the yoke housing portion 52, the main coil insertion portion 53, and the connection leg housing portion 54. Figure 7 is a side view seen along the longitudinal direction of the yoke housing portion 52 and perpendicular to the longitudinal direction of the main coil insertion portion 53 and the connection leg housing portion 54. Figure 8 is a front view seen from a direction perpendicular to the longitudinal direction of the yoke housing portion 52 and parallel to the longitudinal direction of the main coil insertion portion 53 and the connection leg housing portion 54.

The length direction of the main coil insertion portion 53 and the connection leg housing portion 54 is along the winding axis of the main coil 2, and the length direction of the yoke housing portion 52 is the direction in which the main coil insertion portion 53 and the connection leg housing portion 54 are aligned and perpendicular to the winding axis of the main coil 2.

As shown in Figures 5 and 6, a first holding wall 62 extends from the connection leg housing 54, which extends on both sides of the main coil insertion portion 53, toward the main coil insertion portion 53. The first holding wall 62 is a plate piece that extends from the outer surface of the connection leg housing 54 to the insertion portion-facing surface 54a that faces the main coil insertion portion 53. This first holding wall 62 protrudes toward the main coil insertion portion 53 to such an extent that the auxiliary winding 4, whose thickness has been elastically deformed, can pass through the gap between the first holding wall 62 and the main coil insertion portion 53, but the auxiliary winding, which has recovered from elastic deformation and returned to its original diameter, cannot pass through.

The first clamping wall 62 is narrower than the diameter of the auxiliary winding 4 when no external force is applied to reduce its diameter, and extends away from the inner surface 52b of the yoke housing portion 52 by a distance equal to or greater than the diameter of the auxiliary winding 4 when it is subjected to maximum elastic deformation. The inner surface 52b refers to the surface of the yoke housing portion 52 from which the main coil insertion portion 53 and the connection leg housing portion 54 extend.

The auxiliary winding 4, wound to form a ring-shaped portion 42 with one or more turns, is hooked onto the main coil insertion portion 53 and press-fitted into the gap between the first clamping wall 62 and the main coil insertion portion 53, where it is sandwiched between the first clamping wall 62 and the inner surface 52b of the yoke accommodating portion 52. In other words, the inner surface 52b of the yoke accommodating portion 52 becomes the second clamping wall 61 that faces the first clamping wall 62 with a gap between them. The first clamping wall 62 and the second clamping wall 61 then form the fitting portion 6 that supports the auxiliary winding 4 by fitting and clamping the auxiliary winding 4 between them.

The first holding wall 62 extends to each connection leg housing 54 on both sides of the main coil insertion portion 53, so the fitting portions 6 are located on both sides of the main coil insertion portion 53. The pair of fitting portions 6 support the annular portion 42 of the auxiliary winding 4 from two opposing points. If the direction perpendicular to the direction from the connection leg housing 54 toward the main coil insertion portion 53 and perpendicular to the extension direction of the connection leg housing 54 and the main coil insertion portion 53 is referred to as the vertical direction, then the first holding wall 62 only needs to have a predetermined length in the vertical direction to prevent the auxiliary winding 4 from coming loose.

Next, as shown in Figures 7 and 8, an L-shaped portion 7 is formed in the main coil insertion portion 53 of the short-leg resin portion 51 of the core coating resin 5. The L-shaped portion 7 has an abutment wall 72 erected on the main coil insertion portion 53 and a support wall 71 extending from the tip of this abutment wall 72, with the abutment wall 72 and support wall 71 forming an L shape. This L-shaped portion 7 is formed on the winding stop opposite surface 53b opposite the winding stop surface 53a of the main coil insertion portion 53. The winding stop surface 53a is the surface of the main coil insertion portion 58 that faces the same direction as the lattice surface 52a from which the auxiliary winding stopper 55 that fastens the auxiliary winding 4 extends.

The abutment wall 72 rises from the winding stop opposite surface 53b of the main coil insertion portion 53 to a height at least greater than the diameter of the conductor wire of the auxiliary winding 4. The support wall 71 extends in a direction perpendicular or oblique to the rising direction of the abutment wall 72, and extends from its base where it connects to the abutment wall 72 to its tip for a length at least greater than the diameter of the conductor wire of the auxiliary winding 4.

Here, the component of the direction from the abutment wall 72 toward the lead wire 41 of the auxiliary winding 4 that is aligned with the extension direction of the main coil insertion portion 63 is referred to as the lead wire orientation 41a. Furthermore, the direction that extends perpendicular to the abutment surface 72a and points away from the abutment surface 72a, with the abutment surface 72a as its base end, is referred to as the abutment surface orientation 72b. The abutment surface 72a is set so that the component of the abutment surface orientation 72b that is aligned with the extension direction of the main coil insertion portion 63 coincides with the lead wire orientation 41a. In other words, the surface of the abutment wall 72 that faces the lead wire 41 is set as the abutment surface 72a. When the abutment wall 72 extends perpendicular to the winding axis of the main coil insertion portion 53, the lead wire orientation 41a and the abutment surface orientation 72b of the abutment surface 72a are aligned in the same direction. When the abutment wall 72 extends obliquely relative to the winding axis of the main coil insertion portion 53, the angle formed between the lead wire direction 41a and the abutment surface direction 72b is at least less than 90 degrees.

Furthermore, the support wall 71 is bent and extended so that the component of the direction in which the support wall 71 extends from the abutment wall 72 as a base end along the extension direction of the main coil insertion portion 63 is in the same direction as the lead wire direction 41a. When the abutment wall 72 extends perpendicular to the winding axis of the main coil insertion portion 53 and the support wall 71 extends in a direction perpendicular to the abutment wall 72, the support wall 71 is bent and extends in the same direction as the lead wire direction 41a. When the support wall 71 extends in a direction oblique to the abutment wall 72, the support wall 71 is bent and extends so that the angle between the direction in which the support wall 71 extends from the abutment wall 72 as a base end and the lead wire direction 41a is a maximum of less than 90 degrees, preferably in the same direction as the lead wire direction 41a.

The auxiliary winding 4 is wound to form a ring-shaped portion 42, which is a loop of one or more turns, and then hooked onto the main coil insertion portion 53. At this time, the ring-shaped portion 42 of the auxiliary winding 4 is hooked onto the L-shaped portion 7 so that the curved area 42a of the ring-shaped portion 42, which is 180 degrees opposite to the lead wire 41, faces the abutment surface 72a of the abutment wall 72.

When the lead wire 41 is pulled to tighten the annular portion 42 of the auxiliary winding 4, the abutment walls 72 prevent the curved area 42a from moving in the direction opposite the lead wire direction 41a, thereby positioning the annular portion 42 of the auxiliary winding 4. The annular portion 42 is pressed against the pair of fitting portions 6, using the abutment walls 72 as a fulcrum, and enters the gap between the first clamping wall 62 of the fitting portion 6 and the main coil insertion portion 53, becoming wedged and held between the first clamping wall 62 and the second clamping wall 61. Then, by hooking the lead wire 41 onto the auxiliary winding stopper 55, the auxiliary winding 4 is installed in a position precisely determined by both fitting portions 6 and the abutment walls 72 of the L-shaped portion 7.

In addition, the support wall 71 supports the curved area 42a, which is 180 degrees opposite to the lead wire 41, from a direction perpendicular to the surface of the annular portion 42. This prevents the auxiliary winding 4 from loosening, which would cause the annular portion 42 to expand in diameter.

Figure 9 is an enlarged view showing the boundary between the main coil 2 and the auxiliary winding 4. After the auxiliary winding 4 is installed, the main coil 2 is inserted into the main coil insertion portion 58 of the long-leg resin portion 56, while the short-leg resin portion 51 on which the auxiliary winding 4 is installed is connected to the long-leg resin portion 56, completing the core covering resin 5. At this time, as shown in Figure 9, the main coil 2 abuts against the first holding wall 62 of the fitting portion 6. In other words, the first holding wall 62 of the fitting portion 6 acts as a partition, separating the main coil 2 and the auxiliary winding 4 to ensure an insulating distance.

Therefore, the thickness of the first holding wall 62, i.e., the length in the winding axis direction of the main coil 2, may be set to a length that ensures the strength to hold the auxiliary winding 4 without breaking, as well as to ensure an insulating distance between the main coil 2 and the auxiliary winding 4. Furthermore, if the direction perpendicular to the direction from the connection leg housing 54 toward the main coil insertion portion 53 and perpendicular to the extension direction of the connection leg housing 54 and the main coil insertion portion 53 is referred to as the vertical direction, the first holding wall 62 may extend continuously from the upper end to the lower end of the connection leg housing 54 in the vertical direction, or the first holding wall 62 may be formed of multiple protruding pieces arranged at equal intervals and arranged intermittently in the vertical direction. These vertical lengths may also be set to a length that ensures the strength to hold the auxiliary winding 4 without breaking, as well as to ensure insulation between the main coil 2 and the auxiliary winding 4.

As such, the reactor 1 comprises a main coil 2, a core 3, a core coating resin 5, an auxiliary winding 4, and an insertion portion 6. An external current flows through the main coil 2, and the core 3 contains a magnetic material and has the main coil 2 attached to it. The core coating resin 5 covers the core 3 and is interposed between the core 3 and the main coil 2. The auxiliary winding 4 has an annular portion 42 wound with one or more turns, and the magnetic flux of the main coil 2 enters and generates current. The insertion portion 6 extends from the core coating resin 5, and supports the auxiliary winding 4 by being inserted into it.

As a result, once the auxiliary winding 4 has been shaped to form a ring-shaped portion 42, which is a loop of one or more turns, the ring-shaped portion 42 can be hooked onto the main coil insertion portion 53 and the lead wire 41 pulled; the auxiliary winding 4 can then be attached with precision to the desired position, improving the quality of the reactor 1 and allowing the auxiliary winding 4 to accurately capture the magnetic flux of the main coil 2.

For example, the fitting portion 6 has a first sandwiching wall 62 and a second sandwiching wall 61 that face each other with a gap between them, and the annular portion 42 of the auxiliary winding 4 is sandwiched between the first sandwiching wall 62 and the second sandwiching wall 61. Furthermore, the fitting portions 6 are provided at two opposing locations across the annular portion 42 of the auxiliary winding 4.

The fitting portion 6 is not limited to this, and the first clamping wall 62 may be erected on the main coil insertion portion 53 side, or the first clamping wall 62 may be erected on both the insertion portion-facing surface 54a of the connection leg housing 54 and the main coil insertion portion 53, leaving a gap that allows the auxiliary winding 4, which has been reduced in diameter by the application of an external force, to pass through. Furthermore, as long as the fitting portion 6 can support the auxiliary winding 4, it may be provided in one location on either side, or in three or more locations evenly spaced around the circumference.

This first sandwiching wall 62 is a partition that separates the auxiliary winding 4 and the main coil 2. This allows it to function not only as a support for the auxiliary winding 4, but also as a member that insulates the auxiliary winding 4 from the main coil 2.

The auxiliary winding 4 also has lead wires 41 that are drawn out in parallel in the same direction from both ends of the annular portion 42. The reactor 1 also includes a support wall 71 that extends perpendicularly or obliquely to the annular portion 42 and supports the curved region 42a of the annular portion 42 of the auxiliary winding 4 that is 180 degrees opposite to the lead wires 41.

As a result, even if the annular portion 42 tries to expand, it is prevented by the support wall 71. Therefore, the auxiliary winding 4 is wound at a specified radius, preventing it from expanding radially and preventing it from loosening. This allows the auxiliary winding 4 to accurately capture the magnetic flux of the main coil 2 and prevents the reactor 1 from becoming bulky.

The core coating resin 5 also extends toward the annular portion 42 of the auxiliary winding 4 and has an abutment wall 72 that faces the curved area 42a of the annular portion 42 that is 180 degrees opposite the lead wire 41. The abutment wall 72 faces the curved area 42a at the abutment surface 72a, which is the surface on the lead wire 41 side.

As a result, when the lead wire 41 is pulled to tighten the annular portion 42 of the auxiliary winding 4, the abutment walls 72 prevent the curved area 42a from moving in the direction opposite to the lead wire direction 41a, thereby positioning the annular portion 42 of the auxiliary winding 4. Furthermore, the annular portion 42 is pressed against the pair of fitting portions 6, using the abutment walls 72 as a fulcrum, and enters the gap between the first clamping walls 62 of the fitting portions 6 and the main coil insertion portion 53. Therefore, the auxiliary winding 4 is supported in the fitting portions 6 simply and accurately, allowing the auxiliary winding 4 to more accurately capture magnetic flux from the main coil 2, improving the quality of the reactor 1.

Note that the L-shaped portion 7, consisting of the support wall 71 and the abutment wall 72, is erected in the main coil insertion portion 53, but the support wall 71 and the abutment wall 72 may also be provided in separate locations.

The above-described embodiments of the present invention are presented as examples and are not limited to the above-described embodiments. The above-described embodiments can be implemented in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the scope of the invention. The embodiments and their modifications are included within the scope of the present invention.

For example, the abutment wall 72 of the L-shaped portion 7 may extend from the yoke housing portion 52 of the short-leg resin portion 51. Furthermore, the curved area 42a of the annular portion 42 may face the surface of the abutment wall 72 opposite the surface facing the lead wire 41. In this case, the support wall 71 is bent and extended so that the component of the direction in which the support wall 71 extends from the abutment wall 72 as its base end, along the extension direction of the main coil insertion portion 63, is directly opposite the lead wire direction 41a.

1 Reactor 2 Main coil 21 Lead wire 3 Core 31 Yoke portion 32 Fitting leg portion 32a Protrusion portion 32b Disconnection region 33 Connection leg portion 4 Auxiliary winding 41 Lead wire 41a Lead wire direction 42 Annular portion 42a Curved range 5 Core coating resin 51 Short leg resin portion 52 Yoke accommodating portion 52a Lattice surface 52b Inner surface 53 Main coil insertion portion 53a Winding stop surface 53b Winding stop opposite surface 54 Connection leg accommodating portion 54a Insertion portion opposing surface 55 Auxiliary winding stop 56 Long leg resin portion 57 Yoke accommodating portion 58 Main coil insertion portion 59 Connection leg accommodating portion 6 Fitting portion 61 Second holding wall 62 First holding wall 7 L-shaped portion 71 Support wall 72 Abutting wall 72a Abutting surface 72b Abutting surface direction

Claims (8)

a main coil to which an external current is applied;
a core including a magnetic material and on which the main coil is mounted;
a core coating resin that coats the core and is interposed between the core and the main coil;
an auxiliary winding having an annular portion wound with one or more turns, into which magnetic flux from the main coil enters to generate current;
a fitting portion extending from the core coating resin and into which the auxiliary winding is fitted to support the auxiliary winding;
Equipped with
the fitting portions are provided at two locations facing each other across the annular portion of the auxiliary winding;
A reactor characterized by the above. a main coil to which an external current is applied;
a core including a magnetic material and on which the main coil is mounted;
a core coating resin that coats the core and is interposed between the core and the main coil;
an auxiliary winding having an annular portion wound with one or more turns, into which magnetic flux from the main coil enters to generate current;
a fitting portion extending from the core coating resin and into which the auxiliary winding is fitted to support the auxiliary winding;
Equipped with
the auxiliary winding has lead wires drawn out in parallel in the same direction from the annular portion,
the core coating resin has a support wall that extends in a direction perpendicular or oblique to the annular portion and supports a curved area of the annular portion of the auxiliary winding that is 180 degrees opposite to the lead wire;
A reactor characterized by the above. a main coil to which an external current is applied;
a core including a magnetic material and on which the main coil is mounted;
a core coating resin that coats the core and is interposed between the core and the main coil;
an auxiliary winding having an annular portion wound with one or more turns, into which magnetic flux from the main coil enters to generate current;
a fitting portion extending from the core coating resin and into which the auxiliary winding is fitted to support the auxiliary winding;
Equipped with
the auxiliary winding has lead wires drawn out in parallel in the same direction from both ends of the annular portion,
the core-coating resin extends to face the annular portion of the auxiliary winding and has an abutment wall that faces a curved area of the annular portion that is 180 degrees opposite to the lead wire,
the contact wall faces the curved area on the lead wire side;
A reactor characterized by the above. the auxiliary winding has lead wires drawn out in parallel in the same direction from the annular portion,
the core coating resin has a support wall that extends in a direction perpendicular or oblique to the annular portion and supports a curved area of the annular portion of the auxiliary winding that is 180 degrees opposite to the lead wire;
The reactor according to claim 1 , the auxiliary winding has lead wires drawn out in parallel in the same direction from both ends of the annular portion,
the core-coating resin extends to face the annular portion of the auxiliary winding and has an abutment wall that faces a curved area of the annular portion that is 180 degrees opposite to the lead wire,
the contact wall faces the curved area on the lead wire side;
The reactor according to claim 1 , the core coating resin has an L-shaped portion including the support wall,
The L-shaped portion is
a contact wall that extends toward the annular portion of the auxiliary winding and faces a curved area of the annular portion that is 180 degrees opposite to the lead wire;
the support wall extending in a curved manner from the abutment wall;
and
the contact wall faces the curved area on the lead wire side,
the support wall extends from the abutment wall toward the lead wire,
The reactor according to claim 2 or 4 , The insertion portion has a pair of sandwiching walls that face each other with a gap between them,
the annular portion of the auxiliary winding is sandwiched between the pair of sandwiching walls;
The reactor according to any one of claims 1 to 6, characterized in that one of the pair of sandwiching walls is a partition wall separating the auxiliary winding and the main coil;
The reactor according to claim 7 ,