Reactor and DC-DC Converter Using Same

• US 20170229971A1
• Filed: 07/01/2015
• Published: 08/10/2017
• Est. Priority Date: 08/20/2014
• Status: Active Grant

• Current Assignee: Hitachi Astemo Ltd. (Hitachi, Ltd.)
• Original Assignee: Hitachi Automotive Systems Limited (Hitachi, Ltd.)
• Inventors: CHIDA, Tadahiko, GOTO, Akihiro
• Granted Patent: US 10,784,788 B2
• Time in Patent Office: Days
• CPC Class Codes: H01F 27/22 Cooling by heat conduction through solid or powdered fillings
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/28 Coils; Windings; Conductive connections
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2876 Cooling cooling transformers and inductances in general H01F27/08
• CPC Class Codes: H01F 27/32 Insulating of coils, windings, or parts thereof
• CPC Class Codes: H01F 37/00 Fixed inductances not covered by group H01F17/00
• CPC Class Codes: H02M 3/28 using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
• CPC Class Codes: H02M 3/33546 with automatic control of the output voltage or current H02M3/33561 takes precedence

Abstract

An object of the present invention is to provide a small-sized and highly heat-dissipative reactor and a DC-DC converter using the reactor. A reactor according to the present invention includes a plate bus bar, a core, and a heat sink. The core includes a middle leg portion. The heat sink cools the plate bus bar. The plate bus bar is formed such that a winding axis of a winding including the plate bus bar passes through the middle leg portion. A main surface of the plate bus bar is disposed in parallel with a direction of the winding axis and thermally connected to the heat sink via an insulating layer.

Claims

1. A reactor comprising:

a core portion including a middle leg portion;

a plate bus bar wound around the core portion; and

a mold portion configured to seal a part of the plate bus bar,

wherein

the plate bus bar is wound around the middle leg portion such that a main surface of the plate bus bar is disposed in parallel to a direction of a winding axis, and

the mold portion seals the plate bus bar in a state in which a main surface on a side opposite to the middle leg portion side of the plate bus bar is exposed.

2. The reactor according to claim 1,

wherein the plate bus bar comprises:

a first bus bar including a winding portion for providing a first gap between one end and another end;

a second bus bar including a winding portion for providing a second gap between one end and another end; and

a third bus bar different from the first bus bar and the second bus bar,

the first bus bar and the second bus bar are sealed by a mold portion such that a part of the first bus bar and a part of the second bus bar are exposed,

the core portion forms a through hole for penetrating the first bus bar and the second bus bar,

the one end and the other end of the first bus bar and the one end and the other end of the second bus bar are projected from the through hole of the core portion such that the first gap and the second gap are disposed outside of the core portion,

the one end of the first bus bar is connected to the other end of the second bus bar via the third bus bar, and

the mold portion forms an exposed surface on a surface of the first bus bar or the second bus bar disposed on a side opposite to the third bus bar across the core portion.

3. The reactor according to claim 2, comprising an insulating substrate in which the third bus bar is buried.

4. The reactor according to claim 3, comprising a fourth bus bar to be connected to the other end of the first bus bar,

wherein the fourth bus bar includes a terminal unit to be connected to other parts, and

the fourth bus bar is buried in the substrate.

5. The reactor according to claim 4, comprising a fifth bus bar to be connected to the one end of the second bus bar,

wherein the fifth bus bar includes a terminal unit to be connected to other parts, and

the fifth bus bar is buried in the substrate.

6. A plurality of reactors, comprising at least two reactors according to claim 4,

wherein the fourth bus bar of one of the reactors is connected to the first bus bar or the second bus bar of another one of the reactors.

8. The reactor according to claim 1, comprising a heat sink configured to cool the plate bus bar via an insulating layer.

9. A DC-DC converter, comprising:

the reactor according to claim 1, and

a heat sink configured to cool the plate bus bar via an insulating layer.

7. A DC-DC converter, comprising the plurality of reactors according to claim 7.