Reactor and DC-DC Converter Using Same

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.

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

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.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0016] FIG. 1 is a diagram illustrating a circuit configuration of a DC-DC converter.

[0017] FIG. 2(a) is a perspective view illustrating a conventional reactor structure.

[0018] FIG. 2(b) is an exploded perspective view illustrating the conventional reactor structure.

[0019] FIG. 2(c) is a perspective view illustrating a heat dissipation structure of the conventional reactor structure.

[0020] FIG. 3(a) is an external perspective view of a reactor 300 according to an embodiment described herein.

[0021] FIG. 3(b) is an exploded perspective view of the reactor 300.

[0022] FIG. 3(c) is a perspective view for illustrating a heat dissipation structure of the reactor 300.

[0023] FIG. 3(d) is a sectional view on a plane BB′ illustrated in FIG. 3(c).

[0024] FIG. 4(a) is a perspective view illustrating a reactor according to a second embodiment.

[0025] FIG. 4(b) is an exploded perspective view of the reactor according to the second embodiment.

[0026] FIG. 5(a) is a perspective view illustrating a reactor according to a third embodiment.

[0027] FIG. 5(b) is an exploded perspective view illustrating the reactor according to the third embodiment.

[0028] FIG. 5(c) is a perspective view of a wiring body 501 to be used in the reactor according to the third embodiment when viewed from a heat dissipation surface side.

[0029] FIG. 6(a) is a perspective view illustrating a mounting structure of a DC-DC converter using the above-described reactor.

[0030] FIG. 6(b) is an exploded perspective view of the DC-DC converter.

DESCRIPTION OF EMBODIMENTS

[0031] Hereinafter, embodiments of the present invention will be described with reference to drawings.

First Embodiment

[0032] (Basic Structure of Reactor 300)

[0033] FIG. 3(a) is an external perspective view of a reactor 300 according to a first embodiment. FIG. 3(b) is an exploded perspective view of the reactor 300. FIG. 3(c) is a perspective view for illustrating a heat dissipation structure of the reactor 300.

[0034] FIG. 3(d) is a sectional view on a plane BB′ illustrated in FIG. 3(c).

[0035] A structure of the present embodiment will be described with reference to FIGS. 3(a) and 3(b). A core portion 301 including a middle leg portion is disposed by combining E-type cores 301a and 301b, and windings are formed in the middle leg portions 310a and 310b by the plate bus bar 302. Here, a main surface of the plate bus bar 302 is parallel to a winding axis direction of the winding. Connection terminal units 302a and 302b are provided to the plate bus bar 302 to connect to other parts. Thus, by winding the plate bus bar 302, the size of a projected portion of a winding 311 from the core portion 301 can be reduced in comparison with a conventional example. Therefore, the structure enables downsizing of a reactor.

[0036] (Heat Dissipation Structure of Reactor 300)

[0037] As a heat dissipation structure of the above-described reactor 300, a configuration illustrated in FIG. 3(c) is used. As described in a sectional view of FIG. 3(d), a main surface of the plate bus bar 302 disposed on a side opposite to the connection terminal units 302a and 302b across the core 301 is connected to a heat sink 303 via a heat dissipation sheet 304. As a result, a temperature increase can be suppressed by forming a heat dissipation structure of a plate bus bar.

[0038] When the reactor 300 and the heat dissipation structure of the reactor 300 are used, downsizing and high heat dissipation of the reactor 300 can be realized, and a mounting space is not increased as in the conventional example. In addition, as needed, by increasing an area of a main surface of the plate bus bar 302 by being connected to the heat sink 303 via the heat dissipation sheet 304, heat dissipation can be further improved without increasing a size of the reactor 300.

Second Embodiment

[0039] (Reactor Basic Structure)

[0040] FIG. 4(a) is a perspective view illustrating a reactor according to a second embodiment. FIG. 4(b) is an exploded perspective view of the reactor according to the second embodiment. In the first embodiment, a reactor winding is formed by bending a sheet of the plate bus bar 202. However, in the second embodiment, a reactor winding is formed by connecting a plurality of plate bus bars. FIG. 4 illustrates a configuration in which a winding is wound approximately two turns. However, a number of turns can be increased by adding a plate bus bar.

[0041] A core 406 includes an E-type core 406a and an E-type core 406b. The plate bus bars 401 and 402 bent in a U-shape are disposed such that main surfaces becomes parallel to each other, and end portions of the plate bus bars 401 and 402 are disposed so as to project from the through holes 410a and 410b of the core 406. A gap 411b is provided between one end and another end of the plate bus bar 401, and a gap 411a is provided between one end and another end of the plate bus bar 402.

[0042] A plate bus bar 403 which is different from the plate bus bars 401 and 402 is disposed, and one end of the plate bus bar 403 is connected to the plate bus bar 401, and another end is connected to the plate bus bar 402. Further, each of the plate bus bars 404 and 405 for connecting to other parts is connected to the plate bus bars 401 and 402. By connecting a plurality of bus bars in this manner, a winding wound around a middle leg portion of the core 406 can be formed. In the plate bus bar 401, a main surface on a side opposite to a terminal unit across the core 406 is thermally connected to a heat sink 408 via a heat dissipation sheet 407. Accordingly, a heat dissipation surface is formed.

[0043] In the case of forming a winding wound a plurality of turns by bending a sheet of a plate bus bar as in the first embodiment, it becomes difficult to process the plate bus bar depending on a thickness and a width thereof. In addition, in the case where a processing accuracy is not sufficient, gaps between windings needs to be increased to ensure insulation. Consequently, the size of a reactor may be increased. However, in the second embodiment, a winding can be easily formed by combining a plurality of bus bars. In addition, each bus bar has a simple shape, therefore a processing accuracy is superior, and a winding structure can be downsized.

Third Embodiment

[0044] (Reactor Basic Structure)

[0045] FIG. 5(a) is a perspective view illustrating a reactor according to a third embodiment. FIG. 5(b) is an exploded perspective view illustrating the reactor according to the third embodiment. A wiring structure in the third embodiment is same as in the second embodiment. However, a wiring module 501 is formed by sealing the plate bus bars 401 and 402 other than terminal units thereof by a molding material 420. Further, a wiring body 502 is formed by sealing the plate bus bars 403 to 405 by a molding material 421. The wiring body 502 has a plate shape and therefore can be substituted by such as a printed circuit board.

[0046] (Configuration Effect)

[0047] A bus bar and a core can be supported by adding a mechanism for fixing the wiring bodies 501 and 502 to the heat sink 408 by using a screw in molding material portions of the wiring bodies. Further, as illustrated in FIG. 5(c), a heat dissipation path via the heat dissipation sheet 407 can be formed by exposing a plate bus bar on a heat sink side of the wiring body 501.

Fourth Embodiment

[0048] (Structure of DC-DC Converter)

[0049] FIG. 6(a) is a perspective view illustrating a mounting structure of a DC-DC converter 600 using the above-described reactor. FIG. 6(b) is an exploded perspective view of the DC-DC converter 600.

[0050] A DC-DC converter 600 includes a plurality of reactors including a resonance coil, a transformer, a chock coil, and a filter coil.

[0051] A wiring body 602 includes a plurality of wiring bodies having the same configuration as with the wiring body 501 described in the second and third embodiments, and the wiring bodies are integrated with the wiring body 602. In response to a number of the reactors, a plurality of the core portions 603 are provided.

[0052] The wiring body 604 has, for example, a configuration as described below.

[0053] A plurality of the reactors illustrated in FIG. 4(b) in the second embodiment is included, and the plate bus bar 404 of one of the reactors is connected to the plate bus bar 401 or the plate bus bar 402 of another one of the reactors. Further, a housing 601 which functions as a heat sink is thermally connected, via an insulating layer, to an exposed surface of the plate bus bar 401 or the plate bus bar 402 of one of the reactors and an exposed surface of the plate bus bar 401 or the plate bus bar 402 of another one of the reactors.

[0054] The structure described in the third embodiment is applicable in all of the reactor structures described herein, and a DC-DC converter can be downsized by integrating wiring bodies.

REFERENCE SIGNS LIST

[0055] 103a high pressure-side input unit [0056] 103b high pressure-side input unit [0057] 104 smoothing capacitor [0058] 105a to 105d MOSFET [0059] 106 resonance coil [0060] 107 transformer [0061] 108 chock coil [0062] 109 filter coil [0063] 110 smoothing capacitor [0064] 111 filter capacitor [0065] 112 lower pressure-side output unit [0066] 113a and 113b MOSFET [0067] 200 reactor [0068] 201a and 201b core [0069] 201 core portion [0070] 202 plate bus bar [0071] 203 heat sink [0072] 204a and 204b heat dissipation sheet [0073] 301a and 301b core [0074] 301 core portion [0075] 302 plate bus bar [0076] 302a and 302b connection terminal unit [0077] 03 heat sink 304 [0078] heat dissipation sheet [0079] 311 projected portion of winding [0080] 401 to 405 plate bus bar [0081] 406a and 406b core [0082] 406 core portion [0083] 407 heat dissipation sheet [0084] 408 heat sink [0085] 410a and 410b through hole [0086] 411a gap [0087] 411b gap [0088] 420 and 421 molding material [0089] 501 and 502 wiring body [0090] 600 DC-DC converter [0091] 601 housing [0092] 602 and 603 wiring body [0093] 603 core portion