JP2013026418A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor that is superior in assembling workability, and an insulator for the reactor.SOLUTION: A reactor 1 comprises: a coil 2 having cylindrical coil elements 21, 22; a magnetic core 3 having an inner core part 31 arranged in coil elements 21, 22 and an outer core part 32 exposed from the coil 2; and an insulator 4 insulating between the coil 2 and the magnetic core 3. The insulator 4 comprises a frame-like part 41A integrally holding a gap plate 42A. The reactor 1 comprises a composite member 40A the frame-like part 41A in which the frame-like part 41A and a gap plate 42A are united by the insert molding, thereby its assembling workability can be improved.

Description

  The present invention relates to a reactor used as a component of a power converter, a reactor insulator used as a component of the reactor, a converter including the reactor, and a power converter including the converter. In particular, the present invention relates to a reactor excellent in assembly workability.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. For example, Patent Document 1 discloses a reactor used for a circuit component of a converter mounted on a vehicle such as a hybrid vehicle. This reactor includes a coil in which a pair of cylindrical coil elements are arranged side by side, a pair of inner core portions (inner partial cores) respectively disposed in each coil element, and is not housed in the coil element. An annular magnetic core that forms a closed magnetic path with a pair of outer core portions (outer partial cores) exposed from the coil, and an insulator that electrically insulates the coil from the magnetic core.

  The magnetic core is formed by combining a core piece made of a plurality of magnetic materials and a plate-shaped gap spacer made of a plurality of nonmagnetic materials. The insulator includes an inner bobbin formed by combining a pair of] -shaped pieces disposed on the outer periphery of the inner core portion, and a frame-shaped outer bobbin disposed on the end surface of the coil to insulate the coil from the outer core portion. Prepare.

JP 2007-129149 A

  However, the reactor including the conventional insulator is inferior in assembling workability.

  In a conventional reactor, typically, core pieces and gap spacers are alternately laminated to produce an inner core portion, and an inner bobbin of an insulator is disposed on the outer periphery of the inner core portion. The inner core part, the outer bobbin of the insulator, and the outer core part are assembled and manufactured. Thus, in the conventional reactor, since there are many parts, there are many processes and it is inferior to assembly workability. In particular, since the gap spacer is usually a very thin plate material of about 1 mm or less, it is difficult to handle and the assembly workability is also poor in this respect.

  Moreover, when joining a core piece and a gap spacer with an adhesive agent, since it is necessary to harden an adhesive agent for every joining location, a process increases. On the other hand, if the laminated body of the core piece and the gap spacer is integrated with a single adhesive tape, the curing step can be eliminated. However, in this case as well, since the gap spacer is very thin as described above, as described in Patent Document 1, when both end faces of the inner core portion are used as gap spacers, the gap spacers located at both ends by the adhesive tape are used. And it is difficult to join the core pieces adjacent to these gap spacers. It is conceivable to join the gap spacer to the joint surface of the outer core portion with the inner core portion. However, when the joint surface is larger than the gap spacer, it may be difficult to join at an appropriate position. Also from this point, the conventional reactor is inferior in assembly workability.

  Accordingly, one of the objects of the present invention is to provide a reactor having excellent assembly workability. Another object of the present invention is to provide a reactor insulator that can contribute to an improvement in the assembly workability of the reactor. Furthermore, the other object of this invention is to provide the converter which provides the said reactor, and the power converter device which provides this converter.

  The present invention achieves the above object by adopting a configuration in which the outer bobbin (frame portion) of the insulator holds the gap spacer (gap plate) integrally.

  The reactor of the present invention includes a cylindrical coil formed by winding a winding, a magnetic core that forms a closed magnetic path, and an insulator that electrically insulates the coil from the magnetic core. The magnetic core includes an inner core portion disposed in the coil and an outer core portion exposed from the coil. The insulator includes a frame-like portion that insulates the end face of the coil from the outer core portion. The frame-shaped portion integrally holds a gap plate made of a material different from the material of the frame-shaped portion and having a lower magnetic permeability than the magnetic material constituting the magnetic core.

  The reactor insulator according to the present invention is used as a reactor component including a cylindrical coil formed by winding a winding and a magnetic core that is disposed inside and outside the coil to form a closed magnetic path. There is a part for electrically insulating the coil and the magnetic core. The insulator includes a frame-like portion that insulates the outer core portion exposed from the coil and the end surface of the coil, of the magnetic core. The frame-shaped portion integrally holds a gap plate made of a material different from the material of the frame-shaped portion and having a lower magnetic permeability than the magnetic material constituting the magnetic core.

  Note that “insulation” in the insulator means having a withstand voltage characteristic that allows the coil and the magnetic core to be electrically insulated. Further, in the above insulator, “insulating the outer core portion and the end face of the coil” means that the frame-like portion is interposed in addition to the form in which the frame-like portion is directly interposed between the end face of the coil and the outer core portion. Even if not, it includes a form in which the creepage distance between the end face of the coil and the outer core part is increased by the constituent material of the frame-like part.

  Since the frame-shaped part integrally holds the gap plate in the reactor of the present invention and the insulator for the present invention, the frame-shaped part and the gap plate can be handled as one member. Since it is easy to handle the thin gap plate by integrating with the frame-shaped part, when assembling the reactor using the reactor of the present invention or the insulator of the present invention, the above-described core pieces constituting the inner core part and the outer core part are described above. The gap plate can be easily arranged, and the assembly workability is excellent. Moreover, since the frame-shaped part and the gap plate can be handled as one member, the reactor of the present invention and the insulator of the present invention can reduce the number of parts.

  The insulator according to the present invention is easier to handle a thin gap plate by handling the frame portion and the gap plate as one member than when the frame member and the gap spacer are separated and independent members. In addition, the number of parts is small, and the number of reactor assembly processes can be reduced. Therefore, the insulator of this invention can contribute to the improvement of the assembly workability | operativity of a reactor.

  As one form of the reactor of the present invention and the insulator of the present invention, the gap plate may be formed integrally with the frame-shaped part by insert molding and held by the frame-shaped part.

  The said form can manufacture easily the integrated object of the said frame-shaped part and the said gap board, without using fixing agents, such as an adhesive agent and an adhesive tape. Moreover, the said form can integrally mold the gap board of arbitrary shapes to a frame-shaped part easily. From these points, the said form is excellent in the manufacturability of the said integrated object. Furthermore, since the constituent material (mainly resin) of the frame-shaped portion easily holds the gap plate firmly in the above-described form, it is easy to handle the integrated object and is excellent in assembling workability.

  As one form of the reactor of the present invention and the insulator of the present invention, there is a form in which the frame-shaped part and the gap plate are independent members and have engaging parts that engage with each other. In this embodiment, the gap plate is fitted into a through-hole provided in the frame-shaped portion and is held by the frame-shaped portion by the engagement of the engagement portion.

  Since the said form can manufacture the said frame-shaped part and the said gap board separately, the shaping | molding apparatus for integral molding is unnecessary, and various materials can be utilized. And the said form can make it difficult to isolate | separate both the said frame-shaped part and the said gap board integrally by an engaging part, without using the above-mentioned fixing agent. Therefore, in the above-described embodiment, the frame-shaped portion can easily hold the gap plate firmly, so that the integrated body can be easily handled and the assembly workability is excellent.

  As one form of this invention reactor and the insulator of this invention, the form whose thickness of the said gap plate is thicker than the thickness of the location where the said gap plate is fitted in the said frame-shaped part is mentioned.

  In the said form, since a part of gap board fitted by the frame shape part protrudes from a frame shape part, a gap board can contact a core piece more reliably. Therefore, the said form can adjust an inductance accurately. Moreover, the said form can suppress the noise by the vibration of a magnetic core since a gap board and a core piece can closely_contact | adhere.

  The reactor of the present invention can be suitably used as a component part of a converter. The converter of the present invention comprises a switching element, a drive circuit that controls the operation of the switching element, and a reactor that smoothes the switching operation, and converts the input voltage by the operation of the switching element, The form whose said reactor is this invention reactor is mentioned. This converter of the present invention can be suitably used as a component part of a power converter. As a power conversion device of the present invention, a converter for converting an input voltage and an inverter connected to the converter for converting direct current and alternating current are provided, and a load is driven by the power converted by the inverter. And the converter is a converter according to the present invention.

  The converter of the present invention and the power converter of the present invention are excellent in assembling workability by including the reactor of the present invention that is excellent in assembling workability.

  The reactor of the present invention is excellent in assembling workability.

FIG. 2 is a schematic perspective view of the reactor of the first embodiment. (A) is an exploded perspective view of the reactor according to the first embodiment, and (B) is an exploded perspective view of an inner core portion included in the reactor. (A) is a perspective view of a composite member provided in the reactor of Embodiment 1, (a) is a cross-sectional view of this (a)-(a), (B) is a perspective view of another form of composite member, (b) is a cross-sectional view of (b)-(b). (C), (D) is a perspective view of another form of composite member, (c), (d) are (c)-(c) cross-sectional view, (d)-(d) cross-sectional view, respectively. . (A) is a perspective view in the middle of manufacturing another form of composite member, (B) is an exploded perspective view thereof, (C) is an exploded view in the (C)-(C) cross section, (D) is (C)-(C) sectional drawing, (E) is sectional drawing of the composite member of this form. (A) is a perspective view of another form of composite member, (B) is an exploded perspective view, (C) is a (C)-(C) cross-sectional view, and (D) is (C)-(C FIG. FIG. 7 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. FIG. 8 is a schematic circuit diagram showing an example of the power converter of the present invention including the converter of the present invention.

  Embodiments of the present invention will be specifically described below with reference to the drawings. The same reference numerals in the figure indicate the same names.

(Embodiment 1)
Hereinafter, the reactor 1 according to the first embodiment will be described with reference to FIGS. 1 to 3. Reactor 1 is typically installed on a metal (typically aluminum) cooling stand having a refrigerant circulation path (not shown) and the like inside and used as a circuit component. This reactor 1 is arranged between a coil 2, an annular magnetic core 3 in which the coil 2 is arranged on a part of the outer periphery, and between the coil 2 and the magnetic core 3, and between the coil 2 and the magnetic core 3. And an insulator 4 that electrically insulates. The coil 2 includes a pair of cylindrical coil elements 21 and 22, and the magnetic core 3 includes a pair of inner core portions 31 (FIG. 2) disposed in the coil elements 21 and 22, and the coil elements 21 and 22, respectively. A pair of outer core portions 32 exposed from the coil 2 without being disposed inside. A feature of the reactor 1 is that a portion of the insulator 4 that insulates the end surfaces of the coil elements 21 and 22 from the outer core portion 32 has a specific configuration. Hereinafter, each configuration will be described in more detail.

[coil]
The coil 2 (FIGS. 1 and 2) connects a pair of coil elements 21 and 22 formed by spirally winding a single continuous winding 2w having no joint portion, and the coil elements 21 and 22 together. And a connecting portion 23. Each of the coil elements 21 and 22 has the same number of turns and has a hollow cylindrical shape (here, a rectangular shape with rounded corners). These coil elements 21 and 22 are arranged side by side so that their axial directions are parallel, and a part of the winding 2w is bent in a U shape on the other end side of the coil 2 (right side in FIG. 1). Thus, a connecting portion 23 is formed. With this configuration, the winding directions of both coil elements 21 and 22 are the same.

  As the winding 2w, a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof can be suitably used. Here, a coated rectangular wire having an insulating coating made of enamel (typically polyamideimide) on a rectangular copper wire having a rectangular cross-sectional shape is used for the winding 2w. Both coil elements 21 and 22 are edgewise coils formed by winding the coated rectangular wire edgewise. The edgewise coil is easy to increase the space factor and can be a small coil. In addition, the winding 2w can have various conductor cross-sectional shapes such as a circular shape, an elliptical shape, and a polygonal shape. The end face shape and the number of turns of the coil elements 21 and 22 can be appropriately selected. For example, the end face shape can be a cylindrical shape.

  In addition, each coil element can be produced by separate windings, and the ends of the windings forming each coil element can be made into a coil joined by welding, soldering, crimping, or the like.

  Both ends of the winding 2w forming the coil 2 are appropriately extended from the turn forming portion on one end side (left side in FIG. 1) of the coil 2 and separated from the turn forming portion. Then, a terminal fitting (not shown) made of a conductive material is connected to the conductor portion exposed by peeling off the insulating coating. An external device (not shown) such as a power source for supplying power is connected to the coil 2 through the terminal fitting. For connection between the conductor portion of the winding 2w and the terminal fitting, welding such as TIG welding, soldering, or crimping can be used.

[Magnetic core]
The description of the magnetic core 3 will be given mainly with reference to FIG. Of the magnetic core 3, each of the inner core portions 31 inserted into the coil elements 21 and 22 has a shape (a rectangular parallelepiped shape with rounded corners) along the inner peripheral shape of the coil elements 21 and 22, respectively. It is a columnar body. Of the magnetic core 3, the exposed outer core portion 32 that is not inserted into the coil elements 21 and 22 is a columnar body having a pair of trapezoidal surfaces. The outer shape and size of the inner core portion 31 and the outer core portion 32 can be appropriately selected. For example, the inner core portion 31 can be a columnar shape or a rectangular parallelepiped shape, and the outer core portion 32 can be a rectangular parallelepiped shape.

  In the magnetic core 3, an outer core portion 32 is disposed so as to sandwich both inner core portions 31 that are spaced apart from each other, and a gap described later between the end surface 31e of each inner core portion 31 and the inner end surface 32e of the outer core portion 32 is disposed. The plate 42A is sandwiched and formed in an annular shape, and when the coil 2 is excited, a closed magnetic path is formed.

  As shown in FIG. 2 (B), the inner core portion 31 is a laminated body formed by alternately laminating core pieces 31m made of a magnetic material and gap members 31g typically made of a nonmagnetic material (see FIG. 2 (A)), and the outer core portion 32 is a core piece made of a magnetic material. The laminated body and the inner core portion 31 and the outer core portion 32 can be maintained in an annularly combined state by being integrated using an adhesive, an adhesive tape, or the like. In addition, a state in which the magnetic cores 3 are combined in an annular shape may be maintained using a binding band or the like.

  For each core piece, a molded body using magnetic powder or a laminated body in which a plurality of magnetic thin plates (for example, electromagnetic steel plates) having an insulating coating are laminated can be used. The molded body is mainly composed of, for example, an iron group metal such as Fe, Co, Ni, Fe such as Fe-Si, Fe-Ni, Fe-Al, Fe-Co, Fe-Cr, Fe-Si-Al. Powder compacts using powders made of soft magnetic materials such as Fe-based alloys, rare earth metals and amorphous magnetic materials, sintered products obtained by sintering the above powders after press molding, and mixtures of the above powders and resins by injection molding Examples include molded and hardened bodies such as cast molding. In addition, examples of the core piece include a ferrite core that is a sintered body of a metal oxide. The molded body can easily form core pieces having various three-dimensional shapes.

  When a compact having a dielectric coating (typically a silicone resin or phosphate) on the surface of the powder made of the soft magnetic material (especially metal) is used, the eddy current loss may occur. Loss can be reduced. Here, each core piece is a compacted body of soft magnetic powder containing iron such as iron or steel.

  The gap material 31g is a plate-like material disposed between the core pieces for adjusting the inductance, and is made of a material having a lower magnetic permeability than the core pieces. Specific examples of the material include ceramics such as alumina, glass epoxy resin, unsaturated polyester, and polyphenylene sulfide (PPS) resin. In addition, for the gap material 31g, a mixed material in which a magnetic powder (for example, ferrite, Fe, Fe-Si, Sendust) is dispersed in a nonmagnetic material such as ceramics or phenol resin can be used. In particular, the mixed material preferably has a relative permeability of more than 1 and about 10 or less.

  The shape (outer shape) of the core piece and the gap material 31g can be selected as appropriate. Here, each core piece 31m constituting the inner core portion 31 has a rectangular parallelepiped shape (rounded corners of the peripheral surface), and each gap member 31g has a rectangular shape whose end face shape is the same as the core piece 31m. Yes. As long as the gap member 31g can maintain a predetermined distance between the core pieces, the outer shape of the gap member 31g may be different from that of the core piece 31m, and the size of the end face may be different.

  Here, the thicknesses of the gap members 31g are all made uniform and are made thinner than the thickness of the core piece 31m. The thickness of each gap material 31g may be varied. Further, the smaller the thickness of each gap member 31g, the smaller the leakage magnetic flux in the gap portion. As for the thickness of each gap material 31g, 0.2 mm-5 mm are mentioned, for example.

  The number of the core pieces 31m and the gap material 31g, the thickness of the gap material 31g, and the arrangement position of the gap material 31g can be appropriately selected so that the reactor 1 has a desired inductance.

  In addition, in the magnetic core 3 shown in this example, the inner core portion 31 and the outer core portion 32 are not flush with each other in an annularly assembled state. Specifically, when the reactor 1 is installed on an installation target such as a cooling stand, the outer core portion 32 is referred to as the installation side surface (hereinafter referred to as the core installation surface; the lower surface in FIG. 2), and the core installation surface. Each of the opposing surfaces (upper surface in FIG. 2) protrudes from the inner core portion 31. Such a three-dimensional magnetic core 3 can be easily formed by using a core piece made of a compacted body, and the portion of the outer core portion 32 that protrudes from the inner core portion 31 also serves as a magnetic flux passage. Available. Here, the thickness of the outer core portion 32 (the distance between the core installation surface and its opposing surface) is adjusted so as to be flush with the coil 2 when the reactor 1 is assembled. That is, the installation side surface of the reactor 1 includes a core installation surface and a surface on the installation side of the coil 2 (hereinafter referred to as a coil installation surface; the lower surface in FIG. 2). Therefore, the reactor 1 can efficiently transfer the heat of the coil 2 and the magnetic core 3 (outer core portion 32) to the installation target, and is excellent in stability with respect to the installation target.

  In addition, the configuration in which the inner core portion and the outer core portion are flush with each other, only the core installation surface of the outer core portion protrudes from the inner core portion, and the surface facing the core installation surface is flush with the inner core portion. It can be a form or the like.

[Insulator]
The insulator 4 will be described mainly with reference to FIGS. The insulator 4 is in contact with a peripheral wall portion 45 disposed on the outer periphery of the inner core portion 31, and an end surface of each coil element 21, 22, an end surface 31e of the inner core portion 31, and an inner end surface 32e of the outer core portion 32. Plate-like composite member 40A. Reactor 1 is characterized by having a composite member 40A made of a plurality of different materials.

  The peripheral wall portion 45 is a member that insulates between the coil elements 21, 22 and the inner core portion 31, and here, a pair of cross-section pieces divided in the direction orthogonal to the axial direction of the inner core portion 31 Consists of 451,452. The peripheral wall portion 45 can be easily arranged on the outer periphery of the inner core portion 31 by being composed of the divided pieces 451 and 452. The peripheral wall portion 45 shown in this example has a shape in which a part of the inner core portion 31 is exposed when arranged on the inner core portion 31, but covers the entire circumference of the inner core portion 31 when the divided pieces are combined. It is good also as a cylindrical body and can change a shape suitably.

<Form A>
The composite member 40A includes a pair of gap plates 42A sandwiched between a core piece 31m constituting the end of each inner core portion 31 and the outer core portion 32, and a frame-like portion 41A that supports the gap plate 42A. .

The gap plate 42A is a plate-like material formed of the same constituent material as the gap material 31g described above (typically a non-magnetic material such as ceramics such as alumina). Similar to the gap material 31g, the adjustment of inductance is performed. Functions as a member. In particular, the gap plate 42A included in the reactor 1 of the first embodiment has a rectangular outer shape as shown in FIG.3 (A), and its side surface has a thickness as shown in FIG.3 (a). A central portion in the vertical direction is formed by a convex curved surface protruding outward. In addition, in the gap plate 42A shown in this example, the thickness t _g is slightly thicker than the thickness t _{40 of the} portion that holds the gap plate 42A in the frame-like portion 41A described later (t _g > t ₄₀ ), Both surfaces of the front and back surfaces of the gap plate 42A protrude from the above-mentioned holding position in the frame-shaped portion 41A and also protrude from one surface of the frame-shaped portion 41A (this is a composite member 40B of forms B to F described later) The same applies to -40F). Therefore, the gap plate 42A can be in close contact with the core piece 31m and the outer core portion 32, and (1) the inductance can be accurately adjusted by the thickness t _g of the gap plate 42A. (2) Noise due to vibration of the magnetic core 3 The effect that it can suppress can be produced. Note that the thickness t _g of the gap plate 42A can be equal to or less than the thickness t ₄₀ of the portion to be held in the frame-like portion 41A.

  As shown in FIG. 3A, the frame-like portion 41A is a member in which a pair of rectangular openings are arranged side by side when the gap plate 42A is removed. Note that in the composite member 40A and composite members 40B to 40D described later, the gap plates 42A (42B to 42D) are integrally formed on the frame-shaped portion 41A (41B to 41D) by insert molding, and in fact, removed. Can not. 3A, FIG. 3B, FIG. 4C, and FIG. 4D virtually show a state in which one (left side) gap plate 42A (42B to 42D) is removed.

  In the composite member 40A, since the frame-like portion 41A and the gap plate 42A are integrated by insert molding, the gap plate 42A can be fixed to the frame-like portion 41A without using an adhesive or the like. In particular, the gap plate 42A is hooked to the frame-like portion 41A and firmly fixed to the frame-like portion 41A because the side surface held by the frame-like portion 41A is convex as described above. Therefore, the composite member 40A is easy to handle because the gap plate 42A is not easily dropped from the frame-like portion 41A or not when the reactor 1 is assembled. In addition, since both the frame-shaped portion 41A and the gap plate 42A are integrated, the likelihood for attachment is not necessary in both, and the two can be brought into close contact with each other, so that the reactor 1 vibrates due to the likelihood. Can be suppressed. Further, in the reactor 1, even after assembly, the gap plate 42A is difficult to drop off from the frame-like portion 41A, and the gap plate 42A is detached from the frame-like portion 41A so that the gap plate 42A is interposed between the inner core portion 31 and the outer core portion 32. Are not likely to be properly arranged.

  In addition, in the composite member 40A shown in this example, a pair of cylindrical pieces 415 and partition walls 416 projecting from the surface disposed on the inner core portion 31 (FIG. 2) side toward the inner core portion 31 side in the frame-like portion 41A. It is molded integrally with the frame-like portion 41A. The cylindrical piece 415 is a short cylindrical member inserted between the coil elements 21 and 22 (FIG. 2) and the inner core portion 31. The partition wall 416 is provided in the middle part of the pair of gap plates 42A arranged side by side with respect to the frame-shaped part 41A.When the composite member 40A is assembled to the assembly, it is interposed between the coil elements 21 and 22, The two elements 21 and 22 can be prevented from contacting each other, and the distance between the elements 21 and 22 can be easily kept constant. The axial length and circumferential length of the inner core portion 31 of the cylindrical piece 415, the shape of the partition 416, and the like can be appropriately selected, and the cylindrical piece 415 and the partition 416 can be omitted.

  Both the composite members 40A have the same basic configuration, but one (the right side in FIG. 2) composite member 40A includes a base 417 integrally formed with the frame-like portion 41A. The pedestal 417 protrudes toward the outer core portion 32 side in the frame-like portion 41A, and when the composite member 40A is assembled to the above-described assembly, the connecting portion 23 of the coil 2 is placed, and the connecting portion 23 and the outer core Insulates from the part 32.

  The frame-like portion 41A and the peripheral wall portion 45 of the insulator 4 are made of a material having a withstand voltage characteristic such that the coil 2 and the magnetic core 3 can be electrically insulated. For example, insulating materials such as PPS resin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, and liquid crystal polymer (LCP) can be used. Here, PPS resin is used. For forming the frame-like portion 41A, a molding method such as injection molding can be suitably used.

  The composite member 40A is obtained by insert-molding the pair of gap plates 42A as described above using the above material. When insert molding is performed, the gap plate 42A is made of a material (such as the above-described ceramics, unsaturated polyester, PPS resin, etc.) that is not deformed, reacted, or decomposed by pressure or temperature during molding. When the gap plate 42A is made of an insulating material such as alumina, the entire composite member 40A is made of an insulating material and has excellent insulating properties.

[Reactor assembly procedure]
A procedure for forming the reactor 1 having the above configuration will be mainly described with reference to FIG.

  First, the core piece 31m and the gap material 31g are laminated, and the inner core portion 31 shown in FIG. 2 (A) is formed using an adhesive, an adhesive tape, or the like. By using the core piece 31m thicker than the thickness of the gap material 31g instead of the gap material 31g at both end faces of the inner core portion 31, a laminate constituting the inner core portion 31 can be easily formed.

  Also, the constituent material of the frame-like portion 41A and the gap plate 42A are prepared, and the composite member 40A is manufactured by insert molding.

  A structure in which the peripheral wall portion 45 of the insulator 4 is disposed on the outer periphery of each inner core portion 31 is inserted and disposed in the coil elements 21 and 22 of the coil 2. In the assembly of the coil 2 and the inner core portion 31, the composite member 40A and the outer core portions 32 are arranged so as to sandwich both end surfaces of the coil elements 21 and 22 and both end surfaces 31e of the inner core portion 31. In arranging the composite member 40A, the cylindrical piece 415 and the partition 416 provided on the frame-like portion 41A of the insulator 4 can be used as a guide, and the composite member 40A can be easily assembled to the assembly. Through the above steps, the inner core portion 31 and the outer core portion 32 can be assembled in an annular shape with the gap plate 42A of the composite member 40A interposed therebetween to form the annular magnetic core 3.

  For example, an adhesive is applied to both surfaces of the gap plate 42A of the composite member 40A and the inner end surface 32e of the outer core portion 32, and the adhesive is cured to combine the inner core portion 31 and the outer core portion 32. The members 40A may be joined via the gap plate 42A. By this curing step, the annular magnetic core 3 integrated with the adhesive can be formed.

  The reactor 1 is obtained by forming the annular magnetic core 3 as described above. In the obtained reactor 1, the creeping distance between the coil 2 and the outer core portion 32 is increased by the plate-like frame 41A of the composite member 40A, and as a result, the reactor is insulated. In particular, in the reactor 1, since the outer core portion 32 has a shape protruding from the inner core portion 31, the frame-shaped portion 41A is interposed between the outer core portion 32 and the end surfaces of the coil elements 21 and 22. In addition, the outer core portion 32 and the coil 2 are not in contact with each other, so that the insulation can be improved.

[Other configurations]
〔Case〕
Reactor 1 can be used as it is. In addition, for example, it can be configured to be housed in a case (not shown). The case can be made a lightweight and excellent heat-dissipating reactor such as aluminum or an alloy thereof, magnesium or an alloy thereof, if it is lightweight and has excellent thermal conductivity. Further, by storing the reactor 1 in the case, the coil 2 and the magnetic core 3 can be mechanically protected and protected from the environment.

[Outside resin part]
Further, the case in which the reactor 1 is housed can be filled with resin, and the reactor 1 can be sealed with the resin. By providing the sealing resin (outer resin portion), mechanical protection of the coil 2 and the magnetic core 3 and protection from the environment can be more reliably achieved.

  Alternatively, the outer periphery of the reactor 1 may be covered with a resin without being housed in a case, and the resin mold portion (outer resin portion) may be provided on the outer periphery of the reactor 1. In this form, it is possible to reduce weight and reduce the number of parts by not providing a case, and by providing a resin mold part, it is possible to protect the coil 2 and magnetic core 3 from mechanical protection and the environment. Protection can be achieved. A part of the reactor 1, for example, a core installation surface or a coil installation surface may be exposed from the resin mold portion. Since this installation surface can be in direct contact with the installation target, the exposed form can be a reactor having excellent heat dissipation.

  For example, epoxy resin, urethane resin, unsaturated polyester, PPS resin, PBT resin, acrylonitrile-butadiene-styrene (ABS) resin, or the like can be used as the constituent resin of the outer resin portion. In addition, when the constituent resin is mixed with a filler made of at least one ceramic selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide, heat dissipation can be improved.

[Usage]
The reactor 1 having the above-described configuration is used in applications where the energization conditions are, for example, maximum current (DC): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, and operating frequency: about 5 kHz to 100 kHz, typically electric It can be suitably used as a component part of an in-vehicle power conversion device such as an automobile, a hybrid automobile, and a fuel cell automobile.

[effect]
The reactor 1 includes a composite member 40A that integrally holds a gap plate 42A as an insulator 4 that is interposed between the coil 2 and the magnetic core 3 and is electrically insulated. Since the composite member 40A includes the gap plate 42A, the constituent elements of the inner core portion 31 can be reduced and the inner core portion 31 can be easily formed. Further, since the thin gap plate 42A is easily handled by being held by the frame-like portion 41A, the gap plate 42A can be easily disposed between the core piece 31m constituting the inner core portion 31 and the outer core portion 32. Furthermore, the number of parts is small compared to the case where the frame-like portion 41A and the gap plate 42A are separate members. For these reasons, the reactor 1 is excellent in assembling workability.

  In particular, in the composite member 40A, since the frame-shaped portion 41A and the gap plate 42A are integrally formed, it is excellent in manufacturability, and both the frame-shaped portion 41A and the gap plate 42A are difficult to be separated and handled. easy. Also from this point, the reactor 1 is excellent in assembling workability.

  Hereinafter, composite members 40B to 40F of other forms (forms BF) of the composite member including the gap plate will be described. Since the basic configuration and material of the composite members 40B to 40F are the same as the composite member 40A of the form A provided in the reactor 1 of the first embodiment, the description will focus on the differences from the form A. Detailed description of overlapping configurations and effects will be omitted. The composite members 40A to 40F shown in FIGS. 3 to 6 show a form that does not include the pedestal 417 (FIGS. 1 and 2), but may be configured to include the pedestal 417 as described above.

<Form B>
With reference to FIGS. 3 (B) and 3 (b), the composite member 40B of the form B will be described. Similar to the composite member 40A of the form A, the composite member 40B includes a pair of gap plates 42B and a frame-like portion 41B that supports the gap plates 42B. The gap plate 42B is integrated with the frame-like portion 41B by insert molding. It is molded into.

  As with the composite member 40A of the form A, the outer shape of the gap plate 42B is rectangular. However, as shown in FIG. 3 (b), the side surface of the gap plate 42B is formed by a concave curved surface in which the central portion in the thickness direction is recessed inward. The gap plate 42B is hooked on the frame-shaped portion 41B by the constituent material of the frame-shaped portion 41B entering the concave portion. Therefore, the composite member 40B can firmly fix the gap plate 42B to the frame-like portion 41B, like the composite member 40A of the form A, and the gap plate 42B is difficult to drop off from the frame-like portion 41B when the reactor is assembled. Or it is easy to handle without falling off.

<Forms C and D>
A composite member 40C of form C and a composite member 40D of form D will be described with reference to FIG. The composite members 40C (FIG. 4C) and 40D (FIG. 4D) support the pair of gap plates 42C and 42D and the pair of gap plates 42C and 42D, similarly to the composite member 40A of the form A. The gap plates 42C and 42D are formed integrally with the frame-like portions 41C and 41D by insert molding.

  As with the composite member 40A (FIG. 3 (A)) of the form A, the gap plate 42C has a rectangular outer shape and has a convex side surface. However, as shown in FIG. 4C, the side surface of the gap plate 42C is formed in a convex shape by a plurality of planes. As with the composite member 40B (FIG. 3 (B)) of the form B, the gap plate 42D has a rectangular outer shape and a concave side surface. However, as shown in FIG. 4D, the side surface of the gap plate 42D is formed in a concave shape by a plurality of planes.

  These composite members 40C, 40D, like the composite member 40A of the form A and the composite member 40B of the form B, can firmly fix the gap plates 42C, 42D to the frame-like portions 41C, 41D, and at the time of assembling the reactor, etc. The gap plates 42C and 42D are not easily dropped from the frame-like portions 41C and 41D, or are not dropped and easy to handle.

<Form E>
With reference to FIG. 5, the composite member 40E of the form E will be described. In FIGS. 5A and 5B, only one of the pair of gap plates 42E is shown, but the other has the same configuration. This also applies to FIGS. 6A and 6B described later.

The composite member 40E includes a pair of gap plates 42E and a frame-like portion 41E that supports the gap plates 42E, similarly to the composite member 40A of the form A (FIG. 3A). However, the composite member 40E is independent of the frame-like portion 41E and the frame-like portion 41E provided with the through-hole 411 into which the gap plate 42E is fitted, as shown in FIGS. 5 (B) and 5 (C). A gap plate 42E is prepared, and the gap plate 42E is fitted into the through hole 411, and then integrated as shown in FIG. 5 (E). Specifically, before integration, the frame-shaped portion 41E is short on the side disposed on the outer core portion side in the frame-shaped portion 41E (left side in FIG. 5B) as shown in FIG. As shown in FIG. 5 (D), the thickness t ₄₁ of the inner peripheral wall portion that forms the through hole 411 in the frame-like portion 41E is in contact with the inner peripheral wall of the frame-like portion 41E in the gap plate 42E. The outer peripheral edge is thicker than the thickness t ₄₂ (maximum thickness). As will be described later, this cylindrical piece serves as a passage when the gap plate 42E is fitted to a predetermined position.

  As with the gap plate 42C of the form C (FIG. 4C), the gap plate 42E has a rectangular outer shape and has a convex side surface. Here, as shown in FIG. 5 (B) to FIG. 5 (E), the gap plate 42E includes a protrusion 422 over the entire circumference of the side surface thereof.

  Prior to integration, the frame-shaped portion 41E has a pair of through-holes 411 penetrating the front and back as shown in FIG. 5B, and the protrusion 412 protruding from the inner peripheral wall constituting each through-hole 411. With Here, the protrusion 412 is provided on the inner core wall side (the right side in FIG. 5B) on the inner peripheral wall over the entire circumference of the inner peripheral wall. In the through hole 411, the cross-sectional area of the portion where the protrusion 412 is provided is smaller than that of the other portion (see FIG. 5D). That is, the through-hole 411 has a portion having a different cross-sectional area in the thickness direction.

As shown in FIG. 5 (C), when the gap plate 42E is fitted into the through hole 411 of the frame-like portion 41E, as shown in FIG. 5 (D), one surface side region (the thickness of the surface layer) of the gap plate 42E. The thin part is supported by the protrusion 412. The protrusion 412 of the frame-like portion 41E serves as a stopper for the protrusion 422 of the gap plate 42E, and the gap plate 42E is hooked to the frame-like portion 41E. That is, the protrusion 422 functions as a support protrusion that supports the gap plate 42E from one side (here, the inner core portion side) of the through hole 411 of the frame-like portion 41E. Further, as shown in FIG. 5D, the gap plate 42E is sufficiently thicker than the thickness t ₄₂ of the gap plate 42E because the thickness t _{41 of the} portion where the gap plate 42E is fitted in the frame-like portion 41E is sufficiently thick. In addition, while being held by the inner peripheral wall forming the through hole 411 in the frame-like portion 41E, the above-described cylinder piece protrudes from the other side (here, the outer core portion side) of the gap plate 42E. By appropriately melting and deforming the protruding portion, as shown in FIG. 5 (E), a composite member 40E in which the gap plate 42E is sandwiched between the melted portion and the protrusion 412 is obtained. The appearance of the obtained composite member 40E is substantially the same as that of the form D described above. Thus, although the gap plate 42E is not insert-molded in the composite member 40E, a part of the frame-like portion 41E is welded, and the gap plate 42E is sandwiched between the melted portion and the protrusion 412 so that the reactor It is possible to prevent the gap plate 42E from falling off the frame-like portion 41E during assembly or the like. Further, since the composite member 40E can separately manufacture the frame-like portion 41E and the gap plate 42E, the degree of freedom in the manufacturing method is high.

  The protrusion 412 of the frame-like portion 41E only needs to be a stopper for the gap plate 42E. For example, the protrusion 412 may have a protrusion on only a part of the inner peripheral wall in the circumferential direction. Further, when the frame-like portion 41E is provided with a protrusion 412 that can support one surface of the gap plate 42E, the protrusion 422 of the gap plate 42E may be omitted (a flat gap member), or the side surface of the gap plate 42E. It can be set as the form which provides the protrusion 422 only in a part. Furthermore, the short cylinder piece arrange | positioned at the outer core part side can also be made into the protrusion provided only in a part of circumferential direction of the through-hole.

<Form F>
A composite member 40F of form F will be described with reference to FIG. The composite member 40F includes a pair of gap plates 42F and a frame-like portion 41F that supports the gap plates 42F, similarly to the composite member 40A of the form A (FIG. 3A). However, the composite member 40F is an independent member in which the frame-like portion 41F and the gap plate 42F are separable like the composite member 40E of the form E described above (FIG. 5). A through hole 411 into which the plate 42F is fitted is provided. In particular, the composite member 40F has engaging portions that engage with each other in both the frame-like portion 41F and the gap plate 42F.

  As shown in FIG. 6 (B), the gap plate 42F has a rectangular outer shape, and a part of its side surface, here, the central part of each of the four side surfaces has an uneven shape. More specifically, in the gap plate 42F, the surface layer region in the center portion of each side surface is cut out, and the center portion in the thickness direction on the side surface is left to form the protrusion 422. The shape and size of the protrusion 422 can be selected as appropriate. Here, as shown in FIG. 6 (D), the ridge 422 has a surface perpendicular to the plane constituting the portion where the ridge 422 is not provided on the side surface, and an acute angle with respect to this perpendicular surface. It has a right triangle shape formed by intersecting inclined surfaces. The gap plate 42F is fitted so that the inclined surface faces the frame-like portion 41F (FIG. 6 (C)). In addition, one surface (the right side surface in FIG. 6 (D)) arranged on the inner core side in the gap plate 42F has a peripheral portion cut out over the entire circumference, and the opposite surface (in the gap plate 42F) The area is smaller than the surface disposed on the outer core portion side (the left side surface in FIG. 6D). Therefore, as shown in FIG. 6D, the cross section of the peripheral portion of the gap plate 42F has a stepped shape.

  As shown in FIG. 6 (B), the frame-shaped portion 41F has a pair of through-holes 411 penetrating the front and back, and includes two types of protrusions 412 and 413 protruding from the inner peripheral wall constituting each through-hole 411. Yeah.

  One ridge 412 is provided on the inner peripheral wall constituting the through-hole 411 at a position where the right triangle ridge 422 of the gap plate 42F is fitted, and the right triangle ridge 422 of the gap plate 42F and Similarly, it is a right triangle, and has a claw shape as shown in FIG. 6 (D). Specifically, the protrusion 412 of the frame-like portion 41F is formed by a surface perpendicular to the plane constituting the inner peripheral wall of the frame-like portion 41F and an inclined surface that intersects the perpendicular surface at an acute angle. It has a right triangle shape. When the gap plate 42F is attached to the frame-like portion 41F, the inclined surface of the frame-like portion 41F is provided in contact with the inclined surface of the gap plate 42F. Here, the inclined surface of the frame-shaped portion 41F is provided on the side disposed on the outer core portion side in the frame-shaped portion 41F. The formation region of the protrusion 412 can be changed as appropriate according to the protrusion 422.

  The other protrusion 413 is a flat plate and is an L-shaped protrusion. In the circumferential direction of the inner peripheral wall constituting each through-hole 411, the protrusion 412 is not provided (here, four corners). ). A portion of the through hole 411 where the protrusion 413 is provided has a smaller cross-sectional area than other portions (see FIG. 6D). The formation region of the ridge 413 can be changed as appropriate. For example, the ridge 413 may be provided at any three or less corners instead of all the four corners, or the length of the L-shape constituting the ridge 413 is shortened. May be.

  As shown in FIG. 6D, the positions of the protrusions 413,412 described above are different in the position of the through hole 411 in the axial direction. The right-angled triangular protrusion 412 is disposed closer to the outer core portion side in the frame-shaped portion 41F, and the L-shaped protrusion 413 is disposed closer to the inner core portion side in the frame-shaped portion 41F.

  As shown in FIG. 6 (D), the gap plate 42F is fitted into the through hole 411 of the frame-like portion 41F with the smaller cross-sectional area described above (the right side in FIG. 6 (D)). Then, the inclined surface of the right triangular protrusion 422 provided on the gap plate 42F is guided by the inclined surface of the right triangular protrusion 412 provided on the frame portion 41F, and further, when the gap plate 42F is pushed in, the frame 41F elastically deforms, the protrusion 422 of the gap plate 42F gets over the protrusion 412 of the frame-like part 41F, and the vertical surfaces of both protrusions 412 and 422 contact each other as shown in FIG. And engage. That is, the protrusion 412 of the frame-like portion 41F and the protrusion 422 of the gap plate 42F function as an engaging portion. Further, as shown in FIG. 6C, one surface side region of the gap plate 42F is supported by the ridge 413 of the frame-like portion 41F, and the ridge 413 of the frame-like portion 41F corresponds to the ridge 422 of the gap plate 42E. The gap plate 42F is hooked by the stopper, and the gap plate 42F is sandwiched between the protrusions 412 and 413. As described above, the composite member 40F can firmly hold the gap plate 42F by the frame-like portion 41F by both the above-described engaging portion and the stopper.

  Therefore, although the gap plate 42F is not insert-molded in the composite member 40F, the gap plate 42F can be sufficiently held by the above-described engaging portion or the like, and the gap plate 42F is dropped from the frame-like portion 41F when the reactor is assembled. Can be prevented. In particular, the composite member 40F can integrate the gap plate 42F and the frame-like portion 41F with a simple operation as described above. In addition, since the gap plate 42F can firmly hold the gap plate 42F by the engaging portion and can hold the gap plate 42F by the protrusions 412 and 413, the frame-like portion 41F is not easily disengaged and can be more reliably prevented from falling off. From these points, the composite member 40F can contribute to the improvement of the assembly workability of the reactor.

  In the composite member 40F, the thickness (maximum thickness) of the gap plate 42F is slightly larger than the thickness of the portion where the gap plate 42F is fitted (held) in the frame-like portion 41F. It is good.

(Embodiment 2)
In the first embodiment, a mode including a pair of coil elements has been described. In addition, it can be set as the form which provides one cylindrical coil. In this case, the magnetic core includes an inner core portion disposed in the coil, an outer core portion disposed on the outer periphery of the coil, and a pair of end core portions disposed on both end faces of the coil. There are several forms. More specifically, an EE core, an EI core, a pot core having a cross-section EE, or the like can be used.

  In this embodiment, the insulator is a pair of plate-shaped composites that are in contact with the cylindrical peripheral wall portion disposed on the outer periphery of the inner core portion and at least a part of the end surface of the coil and the inner end surface of the end core portion. It is good to have a member. The composite member may be configured to include one gap plate sandwiched between the inner core portion and the end core portion and a frame-like portion that supports the gap plate. In short, in the above-described composite members 40A to 40F, a composite member having only one gap plate 42A to 42F may be used.

(Modification 1)
In the above-described embodiment, the composite members 40A to 40F and the peripheral wall portion 45 have been described as separate members. However, the frame-shaped portion and the peripheral wall portion of the composite members 40A to 40F] are divided pieces. It is possible to form a single piece so that the pair of composite members can be divided in the axial direction of the coil 2. If each of the composite members is provided with engaging portions that engage with each other, the positioning of the divided pieces can be facilitated.

(Modification 2)
Alternatively, the peripheral wall portion 45 is omitted and only the composite members 40A to 40F are formed, and the outer periphery of the inner core portion 31 is formed of, for example, an insulating tube such as a heat-shrinkable tube, an adhesive tape made of an insulating material, or insulating paper. An insulating layer such as a covering layer may be provided.

(Modification 3)
Alternatively, instead of the coating layer, the length of the cylinder piece 415 provided in the frame-like parts 41A to 41F of the composite members 40A to 40F is longer (for example, the length of the cylinder piece is the length of the inner core part 31). It is possible to adopt a form that is about half of that).

(Embodiment I)
The reactors including the reactors of Embodiments 1 and 2 and the composite members 40B to 40F of Forms B to F (hereinafter referred to as the present invention reactors, etc.) are, for example, components of a converter placed on a vehicle or the like, It can utilize for the component of the power converter device which provides this converter.

  For example, a vehicle 200 such as a hybrid vehicle or an electric vehicle is used for traveling by being driven by a main battery 210, a power converter 100 connected to the main battery 210, and power supplied from the main battery 210, as shown in FIG. Motor (load) 220 to be provided. The motor 220 is typically a three-phase AC motor, which drives the wheel 250 during traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, the vehicle 200 includes an engine in addition to the motor 220. In FIG. 7, an inlet is shown as a charging point of the vehicle 200, but a form including a plug may be adopted.

  The power conversion apparatus 100 includes a converter 110 connected to the main battery 210 and an inverter 120 connected to the converter 110 and performing mutual conversion between direct current and alternating current. Converter 110 shown in this example boosts the DC voltage (input voltage) of main battery 210 of about 200V to 300V to about 400V to 700V and supplies power to inverter 120 when vehicle 200 is traveling. Converter 110 steps down DC voltage (input voltage) output from motor 220 via inverter 120 during regeneration to DC voltage suitable for main battery 210 to charge main battery 210. The inverter 120 converts the direct current boosted by the converter 110 into a predetermined alternating current when the vehicle 200 is running and supplies power to the motor 220. During regeneration, the alternating current output from the motor 220 is converted into direct current and output to the converter 110. doing.

  As shown in FIG. 8, the converter 110 includes a plurality of switching elements 111, a drive circuit 112 that controls the operation of the switching elements 111, and a reactor L, and converts input voltage by ON / OFF repetition (switching operation). (In this case, step-up / down). For the switching element 111, a power device such as an FET or an IGBT is used. The reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that tends to prevent the change of the current to flow through the circuit. The reactor L includes the reactor according to the present invention. By providing the reactor of the present invention that is excellent in assembling workability, the power conversion device 100 and the converter 110 are excellent in assembling workability.

  The vehicle 200 is connected to the converter 110, the power supply device converter 150 connected to the main battery 210, the sub battery 230 serving as the power source of the auxiliary machinery 240, and the main battery 210. Auxiliary power converter 160 for converting high voltage to low voltage is provided. The converter 110 typically performs DC-DC conversion, while the power supply device converter 150 and the auxiliary power supply converter 160 perform AC-DC conversion. Some of the power supply device converters 150 perform DC-DC conversion. The reactor of the power supply device converter 150 or the auxiliary power supply converter 160 may have a configuration similar to that of the reactor of the present invention, and a reactor whose size and shape are appropriately changed can be used. Further, the reactor of the present invention can be used for a converter that performs conversion of input power and that only performs step-up or only performs step-down.

  Note that the present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the gist of the present invention. For example, the configuration of the engaging portion described in the form F can be changed. Specifically, for example, projections 412 and 413 are provided on the frame-like portion (the width of the projection 412 may be narrower), and the inclined surface in which the side surface of the gap plate is inclined from one surface to the other surface of the gap plate In other words, the gap plate is shaped like a square frustum. In this configuration, the gap plate can be easily fitted into the frame-shaped portion, and the shape of the gap plate is simple, and the productivity of the gap plate is excellent.

  The reactor of the present invention can be suitably used for various types of reactors (on-vehicle parts, parts for power generation / transforming equipment, etc.). In particular, the reactor of the present invention can be used as a component of a power conversion device such as a DC-DC converter mounted on a vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle. The converter of the present invention and the power converter of the present invention can be used for various applications such as in-vehicle use and power generation / transformation equipment.

1 Reactor
2 coils
2w Winding 21,22 Coil element 23 Connecting part
3 Magnetic core
31 Inner core 31m Core piece 31g Gap material 31e End face
32 Outer core part 32e Inner end face
4 Insulator
40A, 40B, 40C, 40D, 40E, 40F Composite material
41A, 41B, 41C, 41D, 41E, 41F Frame
411 Through hole 412,413 Projection 415 Tube piece 416 Bulkhead 417 Base
42A, 42B, 42C, 42D, 42E, 42F Gap plate 422 Projection
45 Perimeter wall 451,452 Split piece
100 Power converter 110 Converter 111 Switching element
112 Drive circuit
120 Inverter 150 Power supply converter 160 Auxiliary power converter
200 Vehicle 210 Main battery 220 Motor 230 Sub battery
240 accessories 250 wheels

Claims (7)

A cylindrical coil formed by winding a winding, a magnetic core that forms a closed magnetic path with an inner core portion disposed in the coil and an outer core portion exposed from the coil, and the coil and the magnetic core A reactor including an insulator that electrically insulates between,
The insulator includes a frame-like portion that insulates the end face of the coil from the outer core portion,
The frame-shaped portion is a material different from the material of the frame-shaped portion, and integrally holds a gap plate made of a material having a lower magnetic permeability than the magnetic material constituting the magnetic core. Reactor to do.   2. The reactor according to claim 1, wherein the gap plate is integrally formed with the frame-shaped portion by insert molding and is held by the frame-shaped portion. The frame-shaped portion and the gap plate are independent members and have engaging portions that engage with each other.
2. The reactor according to claim 1, wherein the gap plate is fitted into a through-hole provided in the frame-shaped portion and is held by the frame-shaped portion by the engagement of the engagement portion.   The reactor according to any one of claims 1 to 3, wherein the gap plate is thicker than a portion of the frame-like portion where the gap plate is fitted. A converter comprising a switching element, a drive circuit that controls the operation of the switching element, and a reactor that smoothes the switching operation, and converts the input voltage by the operation of the switching element,
The converter according to any one of claims 1 to 4, wherein the reactor is a reactor according to any one of claims 1 to 4. A converter for converting an input voltage, and an inverter connected to the converter for converting between direct current and alternating current, and for driving a load with electric power converted by the inverter,
The power converter according to claim 5, wherein the converter is the converter according to claim 5. A reactor insulator for electrically insulating between a cylindrical coil formed by winding a winding and a magnetic core disposed inside and outside the coil to form a closed magnetic path,
Of the magnetic core, comprising a frame-like portion that insulates the outer core portion exposed from the coil and the end face of the coil,
The frame-shaped portion is a material different from the material of the frame-shaped portion, and integrally holds a gap plate made of a material having a lower magnetic permeability than the magnetic material constituting the magnetic core. Reactor insulator to be used.

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