JP2021114499A - Reactor - Google Patents

Abstract

To reduce a manufacturing step and a manufacturing cost, while suppressing an increase in size reactor due to an installation of a plurality of coils in a reactor.SOLUTION: A reactor 10 comprises: a first coil 12 wound to two upper and lower layers with α winding; a second coil 14 wound to the two upper and lower layers with α winding. The first and second coils 12 and 14 are arranged along an axial direction of a winding axis L. The first coil 12 comprises: a first upper layer 22 which becomes an upper step and a small diameter while having less the number of windings; and a first lower layer 24 which becomes a lower step and a large diameter while having larger number of windings. The second coil 14 comprises: a second upper layer 30 which becomes the upper step, and in which the number of windings is small, and which becomes a small diameter; and a second lower layer 32 which becomes the lower step, in which the number of windings is large, and which becomes a large diameter. A second end part 26 fetched out from the first lower layer 24 in the first coil 12 and a fourth end part 34 fetched out from the second lower layer 32 in the second coil 14 are coupled on an outer peripheral side of the second upper layer 30 as a coupling part 36, and the coupling part 36 is housed in a space 38 on the outer peripheral side.SELECTED DRAWING: Figure 1

Description

本発明は、α巻きでコイルをボビンに巻回してコアの内部へと収納したリアクトルに関する。 The present invention relates to a reactor in which a coil is wound around a bobbin by α-winding and stored inside a core.

従来から、断面矩形状の平角線がα巻きで２段に巻回されたコイルと、該コイルの収納されるコアとを有したリアクトルが知られており、例えば、特許文献１に開示されるリアクトルでは、コイルを２つ設けてコアに対して同一平面状となるように並べて配置すると共に、該コイルの周方向に沿って同一方向へ電流が流れるようにコイル同士を電気的に接続している。これにより、単一のコイルでリアクトルを構成する場合と比較し、２つのコイルから大きいインダクタンスを得ることを可能としている。 Conventionally, a reactor having a coil in which a flat wire having a rectangular cross section is wound in two stages by α winding and a core in which the coil is housed is known, and is disclosed in, for example, Patent Document 1. In the reactor, two coils are provided and arranged side by side so as to be in the same plane with respect to the core, and the coils are electrically connected to each other so that current flows in the same direction along the circumferential direction of the coils. There is. This makes it possible to obtain a large inductance from two coils as compared with the case where the reactor is composed of a single coil.

特開２０１４−３３０３７号公報Japanese Unexamined Patent Publication No. 2014-33037

上述したリアクトルでは、２つのコイルを備えることで大きなインダクタンスが得られる一方で、前記コイルをコアにおいて同一平面上に並べて配置する構成としているため、その設置面積が大きくなってしまうという問題がある。 In the reactor described above, a large inductance can be obtained by providing two coils, but since the coils are arranged side by side on the same plane in the core, there is a problem that the installation area becomes large.

また、２つのコイルを巻回軸に沿って同軸状となるように積層させ、その設置面積を抑制することが考えられるが、一方のコイルと他方のコイルとを外周側で互いに接続することが難しく、しかも、前記コイルの最大外周径となる外周面に対して接続部位がさらに外側へと突出してしまう。従って、コイルの外側を覆うコアに対して接続部位を収納するための凹部等のスペースが必要となり、前記コアを含むリアクトルの製造工程や製造コストが増加してしまうと共に、コアの内周径を拡大することでリアクトルが径方向へ大型化してしまうこととなる。 Further, it is conceivable to stack the two coils so as to be coaxial along the winding axis to reduce the installation area, but it is possible to connect one coil and the other coil to each other on the outer peripheral side. Moreover, it is difficult, and the connection portion protrudes further outward with respect to the outer peripheral surface which is the maximum outer peripheral diameter of the coil. Therefore, a space such as a recess for accommodating the connection portion is required for the core covering the outside of the coil, which increases the manufacturing process and manufacturing cost of the reactor including the core and increases the inner diameter of the core. By enlarging, the reactor will become larger in the radial direction.

本発明は、前記の課題を考慮してなされたものであり、複数のコイルを設けることによる大型化を抑制しつつ、製造工程及び製造コストの削減を図ることが可能なリアクトルを提供することを目的とする。 The present invention has been made in consideration of the above-mentioned problems, and provides a reactor capable of reducing a manufacturing process and a manufacturing cost while suppressing an increase in size due to the provision of a plurality of coils. The purpose.

前記の目的を達成するために、本発明の態様は、α巻きで上下２層に巻回された第１コイルと、α巻きで上下２層に巻回された第２コイルとを備えたリアクトルにおいて、
第１コイルは、一方の層を構成し巻き数の少ない第１小径巻回部と、他方の層を構成し第１小径巻回部に対して巻き数の多い第１大径巻回部とを有し、
第２コイルは、一方の層を構成し巻き数の少ない第２小径巻回部と、他方の層を構成し第２小径巻回部に対して巻き数の多い第２大径巻回部とを有し、
第１コイルと第２コイルとが巻回軸の軸方向に沿って同軸状に配置され、第１小径巻回部及び第２小径巻回部の少なくとも一方が、第１大径巻回部及び第２大径巻回部の間となるように配置されると共に、第１コイルと第２コイルとを電気的に接続する連結部が、第１小径巻回部及び第２小径巻回部の少なくとも一方の外周側に配置される。 In order to achieve the above object, the aspect of the present invention is a reactor including a first coil wound in two upper and lower layers by α winding and a second coil wound in two upper and lower layers by α winding. In
The first coil has a first small-diameter winding portion that constitutes one layer and has a small number of turns, and a first large-diameter winding portion that constitutes the other layer and has a large number of turns with respect to the first small-diameter winding portion. Have,
The second coil has a second small-diameter winding portion that constitutes one layer and has a small number of turns, and a second large-diameter winding portion that constitutes the other layer and has a large number of turns with respect to the second small-diameter winding portion. Have,
The first coil and the second coil are arranged coaxially along the axial direction of the winding shaft, and at least one of the first small-diameter winding portion and the second small-diameter winding portion is the first large-diameter winding portion and the second small-diameter winding portion. It is arranged so as to be between the second large-diameter winding part, and the connecting part that electrically connects the first coil and the second coil is the first small-diameter winding part and the second small-diameter winding part. It is arranged on at least one outer peripheral side.

本発明によれば、α巻きで上下２層に巻回された第１コイルと、α巻きで上下２層に巻回された第２コイルとを、その巻回軸の軸方向に沿って配置してリアクトルを構成する際、第１コイルにおいて一方の層を構成し巻き数の少ない第１小径巻回部と、第２コイルにおいて一方の層を構成し巻き数の少ない第２小径巻回部の少なくともいずれか一方を、巻き数が多く大径となる第１コイルの第１大径巻回部及び第２コイルの第２大径巻回部の間となるように配置すると共に、第１コイルと第２コイルとを電気的に接続する連結部を、第１小径巻回部及び第２小径巻回部の少なくとも一方の外周側へと配置している。 According to the present invention, the first coil wound in two upper and lower layers by α winding and the second coil wound in two upper and lower layers by α winding are arranged along the axial direction of the winding axis. When the reactor is constructed, the first small-diameter winding portion which forms one layer in the first coil and has a small number of turns and the second small-diameter winding portion which forms one layer in the second coil and has a small number of turns. At least one of the above is arranged so as to be between the first large-diameter winding portion of the first coil and the second large-diameter winding portion of the second coil, which have a large number of turns and a large diameter, and the first A connecting portion that electrically connects the coil and the second coil is arranged on the outer peripheral side of at least one of the first small diameter winding portion and the second small diameter winding portion.

従って、第１小径巻回部及び第２小径巻回部の外周側には、第１及び第２大径巻回部に対して径方向に空間を有しているため、この空間内に連結部を配置することで、第１及び第２コイルの最外周径となる第１及び第２大径巻回部に対して連結部が外側へと突出してしまうことがない。 Therefore, since the outer peripheral side of the first small diameter winding portion and the second small diameter winding portion has a space in the radial direction with respect to the first and second large diameter winding portions, it is connected in this space. By arranging the portions, the connecting portion does not protrude outward with respect to the first and second large diameter winding portions, which are the outermost outer diameters of the first and second coils.

その結果、第１及び第２コイルを巻回軸の軸方向に沿って積層させることで、従来技術に係るリアクトルと比較して設置面積を削減して大型化を抑制しつつ大きなインダクタンスを得ることができると共に、連結部を第１及び第２コイルに対して外側に突出させることなく配置できるため、第１及び第２コイルが径方向に大型化してしまうことがなく、しかも連結部を収納するための凹部等をコアに設ける必要がないため、リアクトルにおける製造工程及び製造コストの増加を回避することができる。 As a result, by stacking the first and second coils along the axial direction of the winding shaft, the installation area can be reduced and a large inductance can be obtained while suppressing the increase in size as compared with the reactor according to the prior art. Since the connecting portion can be arranged without protruding outward from the first and second coils, the first and second coils do not become large in the radial direction, and the connecting portion is housed. Since it is not necessary to provide a recess or the like for the core in the core, it is possible to avoid an increase in the manufacturing process and the manufacturing cost in the reactor.

本発明によれば、以下の効果が得られる。 According to the present invention, the following effects can be obtained.

すなわち、リアクトルを構成する第１及び第２コイルを巻回軸の軸方向に沿って配置し、第１コイルにおいて一方の層を構成し巻き数が少ない第１小径巻回部と、第２コイルにおいて一方の層を構成し巻き数が少ない第２小径巻回部の少なくともいずれか一方を、巻き数が多く大径となる第１コイルの第１大径巻回部及び第２コイルの第２大径巻回部の間となるように配置すると共に、第１コイルと第２コイルとを電気的に接続する連結部を、第１小径巻回部及び第２小径巻回部の少なくとも一方の外周側に配置している。 That is, the first and second coils constituting the reactor are arranged along the axial direction of the winding shaft, and one layer is formed in the first coil, and the first small-diameter winding portion having a small number of turns and the second coil The first large-diameter winding portion of the first coil and the second coil of the second coil have a large number of turns and a large diameter at least one of the second small-diameter winding portions that form one layer and have a small number of turns. It is arranged so as to be between the large-diameter winding portions, and the connecting portion that electrically connects the first coil and the second coil is provided at least one of the first small-diameter winding portion and the second small-diameter winding portion. It is arranged on the outer peripheral side.

その結果、第１大径巻回部と第２大径巻回部との間において、第１小径巻回部及び第２小径巻回部の外周側に径方向の空間を確保できるため、この空間内に連結部を配置することで、第１及び第２コイルの最外周径となる第１及び第２大径巻回部に対して連結部が外側へと突出してしまうことがない。 As a result, a radial space can be secured between the first large-diameter winding portion and the second large-diameter winding portion on the outer peripheral side of the first small-diameter winding portion and the second small-diameter winding portion. By arranging the connecting portion in the space, the connecting portion does not protrude outward with respect to the first and second large diameter winding portions which are the outermost outer diameters of the first and second coils.

その結果、第１及び第２コイルを巻回軸の軸方向に沿って積層させることで、従来技術に係るリアクトルと比較して設置面積を削減して大型化を抑制しつつ大きなインダクタンスを得ることができると共に、連結部を第１及び第２コイルに対して外側へと突出させることなく配置することで、第１及び第２コイルが径方向に大型化してしまうことがなく、しかも連結部を収納するための凹部等をコアに設ける必要がないため、リアクトルにおける製造工程及び製造コストを削減することができる。 As a result, by stacking the first and second coils along the axial direction of the winding shaft, the installation area can be reduced and a large inductance can be obtained while suppressing the increase in size as compared with the reactor according to the prior art. By arranging the connecting portion without protruding outward with respect to the first and second coils, the first and second coils do not become large in the radial direction, and the connecting portion can be formed. Since it is not necessary to provide a recess or the like for storing in the core, the manufacturing process and manufacturing cost in the reactor can be reduced.

本発明の第１の実施の形態に係るリアクトルの一部切欠外観斜視図である。It is a partial cutout appearance perspective view of the reactor which concerns on 1st Embodiment of this invention. 図２Ａは、図１に示すリアクトルを連結部側から見た側面図であり、図２Ｂは、図２Ａに示すリアクトルの背面図である。FIG. 2A is a side view of the reactor shown in FIG. 1 as viewed from the connecting portion side, and FIG. 2B is a rear view of the reactor shown in FIG. 2A. 図３Ａは、本発明の第２の実施の形態に係るリアクトルを連結部側から見た側面図であり、図３Ｂは、図３Ａに示すリアクトルの背面図である。FIG. 3A is a side view of the reactor according to the second embodiment of the present invention as viewed from the connecting portion side, and FIG. 3B is a rear view of the reactor shown in FIG. 3A. 図４Ａは、本発明の第３の実施の形態に係るリアクトルを連結部側から見た側面図であり、図４Ｂは、図４ＡのＩＶＢ−ＩＶＢ線に沿った断面図である。FIG. 4A is a side view of the reactor according to the third embodiment of the present invention as viewed from the connecting portion side, and FIG. 4B is a cross-sectional view taken along the IVB-IVB line of FIG. 4A. 図５Ａは、本発明の第４の実施の形態に係るリアクトルを連結部側から見た側面図であり、図５Ｂは、図５ＡのＶＢ−ＶＢ線に沿った断面図である。FIG. 5A is a side view of the reactor according to the fourth embodiment of the present invention as viewed from the connecting portion side, and FIG. 5B is a cross-sectional view taken along the line VB-VB of FIG. 5A.

本発明に係るリアクトルについて好適な実施の形態を挙げ、添付の図面を参照しながら以下詳細に説明する。 Suitable embodiments of the reactor according to the present invention will be given and will be described in detail below with reference to the accompanying drawings.

この第１の実施の形態に係るリアクトル１０は、図１〜図２Ｂに示されるように、一組の第１及び第２コイル１２、１４と、該第１及び第２コイル１２、１４が外周側に巻回される円筒状のボビン１６と、前記第１及び第２コイル１２、１４及び前記ボビン１６の収納されるコア１８とを含む。 In the reactor 10 according to the first embodiment, as shown in FIGS. 1 to 2B, a set of the first and second coils 12 and 14 and the first and second coils 12 and 14 are outer circumferences. It includes a cylindrical bobbin 16 wound sideways, the first and second coils 12, 14 and a core 18 in which the bobbin 16 is housed.

第１及び第２コイル１２、１４は、例えば、エナメル等の絶縁被膜で覆われ導電性を有した平角導線がそれぞれ用いられ、その幅広面が径方向となるように、上下方向（矢印Ａ１、Ａ２方向）に２層にわたってそれぞれα巻きでボビン１６の外周側へと巻回されている。 For the first and second coils 12, 14, for example, flat conductors covered with an insulating film such as enamel and having conductivity are used, respectively, and the wide surface thereof is in the radial direction in the vertical direction (arrows A1, It is wound around the outer circumference of the bobbin 16 by α winding over two layers in the A2 direction).

第１コイル１２は、第２コイル１４に対して上方（矢印Ａ１方向）に設けられ、その一端となる第１端部２０から内側に向かって複数回巻回されて第１上層（第１小径巻回部）２２を構成し、該第１上層２２の途中において下方へと移動した後に、外側に向かって第１上層２２よりも多い巻き数で巻回して第１下層（第１大径巻回部）２４を構成している。 The first coil 12 is provided above the second coil 14 (in the direction of arrow A1), and is wound a plurality of times inward from the first end portion 20 which is one end thereof to form a first upper layer (first small diameter). The winding portion) 22 is formed, and after moving downward in the middle of the first upper layer 22, the first lower layer (first large-diameter winding) is wound outward with a larger number of turns than the first upper layer 22. (Coil) 24.

そして、第１端部２０は、第１上層２２において最も外周側から直線状に引き出され、絶縁被膜に覆われず導電可能に露呈しており、一方、第２端部２６は、第１コイル１２の他端となり、第１下層２４の外周面２４ａから巻回軸Ｌの軸方向に沿って第２コイル１４側（矢印Ａ２方向）へと略直角に折曲されて引き出され、前記第１下層２４の下端に対して下方へと所定長さだけ突出している。 The first end portion 20 is linearly drawn out from the outermost outer peripheral side in the first upper layer 22, and is electrically exposed without being covered with the insulating film, while the second end portion 26 is the first coil. It becomes the other end of the twelve, is bent at a substantially right angle from the outer peripheral surface 24a of the first lower layer 24 to the second coil 14 side (arrow A2 direction) along the axial direction of the winding shaft L, and is pulled out. It protrudes downward by a predetermined length with respect to the lower end of the lower layer 24.

すなわち、第１コイル１２では、第１上層２２に対して第１下層２４が巻き数が多く形成され、前記第１上層２２の最外周径Ｂ１（図２Ｂ参照）に対して第１下層２４の最外周径Ｂ２（図２Ｂ参照）が大きくなるように形成される（Ｂ１＜Ｂ２）。換言すれば、第１コイル１２は、第１上層２２が小径に形成され、第１下層２４が大径となるように形成される。なお、第１コイル１２における第１上層２２及び第１下層２４の内周径は略同一に形成される。 That is, in the first coil 12, the first lower layer 24 has a larger number of turns than the first upper layer 22, and the first lower layer 24 has a larger number of turns than the outermost outer diameter B1 (see FIG. 2B) of the first upper layer 22. It is formed so that the outermost outer diameter B2 (see FIG. 2B) becomes large (B1 <B2). In other words, the first coil 12 is formed so that the first upper layer 22 has a small diameter and the first lower layer 24 has a large diameter. The inner peripheral diameters of the first upper layer 22 and the first lower layer 24 in the first coil 12 are formed to be substantially the same.

第２コイル１４は、第１コイル１２の下方（矢印Ａ２方向）に同軸状に設けられ、その一端となる第３端部２８から内側に向かって複数回巻回されて第２上層（第２小径巻回部）３０を構成し、該第２上層３０の途中において下方へと移動した後に、外側に向かって前記第２上層３０よりも多い巻き数で巻回して第２下層（第２大径巻回部）３２を構成する。この第３端部２８は、第２下層３２において最も外周側から直線状に引き出され、絶縁被膜に覆われず導電可能に露呈すると共に、第２コイル１４が第１コイル１２と巻回軸Ｌの軸方向に沿って積層された際、第１端部２０と同一方向となるように略平行に延在している（図１及び図２Ａ参照）。 The second coil 14 is coaxially provided below the first coil 12 (in the direction of arrow A2), and is wound a plurality of times inward from the third end 28, which is one end thereof, to form a second upper layer (second). The small-diameter winding portion) 30 is formed, and after moving downward in the middle of the second upper layer 30, the second lower layer (second large) is wound outward with a larger number of turns than the second upper layer 30. Diameter winding portion) 32 is configured. The third end portion 28 is linearly drawn out from the outermost outer peripheral side in the second lower layer 32 and is electrically exposed without being covered with the insulating film, and the second coil 14 is the first coil 12 and the winding shaft L. When laminated along the axial direction of, the coils extend substantially in parallel with the first end portion 20 (see FIGS. 1 and 2A).

そして、第２コイル１４の他端となる第４端部３４は、第２下層３２の外周面３２ａから巻回軸Ｌの軸方向に沿って第１コイル１２側（矢印Ａ１方向）へと略直角に折曲され引き出され、第２上層３０側に向かって延在すると共に、前記第２下層３２の上端よりも上方へ突出している。 The fourth end 34, which is the other end of the second coil 14, is substantially from the outer peripheral surface 32a of the second lower layer 32 toward the first coil 12 side (arrow A1 direction) along the axial direction of the winding shaft L. It is bent at a right angle and pulled out, extending toward the second upper layer 30 side, and protruding upward from the upper end of the second lower layer 32.

すなわち、第２コイル１４における第２上層３０に対して第２下層３２が巻き数が多く形成され、前記第２上層３０の最外周径Ｂ３（図２Ｂ参照）に対して前記第２下層３２の最外周径Ｂ４（図２Ｂ参照）が大きくなるように形成される（Ｂ３＜Ｂ４）。換言すれば、第２コイル１４は、第２上層３０が小径に形成され、第２下層３２が大径となるように形成される。一方、上述した第２上層３０及び第２下層３２の内周径は略同一に形成される。 That is, the second lower layer 32 has a larger number of turns than the second upper layer 30 of the second coil 14, and the second lower layer 32 has a larger number of turns than the outermost outer diameter B3 (see FIG. 2B) of the second upper layer 30. It is formed so that the outermost outer diameter B4 (see FIG. 2B) becomes large (B3 <B4). In other words, the second coil 14 is formed so that the second upper layer 30 has a small diameter and the second lower layer 32 has a large diameter. On the other hand, the inner peripheral diameters of the second upper layer 30 and the second lower layer 32 described above are formed to be substantially the same.

上述したように、第１及び第２コイル１２、１４は、その巻回軸Ｌの軸方向（矢印Ａ１、Ａ２方向）に積層された際、巻き数が少なく小径の第１上層２２及び第２上層３０と、大径の第１下層２４及び第２下層３２とが前記軸方向に沿って交互となるように配置されている。 As described above, when the first and second coils 12 and 14 are laminated in the axial direction (arrows A1 and A2 directions) of the winding shaft L, the first upper layer 22 and the second coil having a small number of turns and a small diameter are used. The upper layer 30, the large-diameter first lower layer 24, and the second lower layer 32 are arranged so as to alternate along the axial direction.

なお、第２上層３０の巻き数は、第１コイル１２の第１上層２２と同数となり、第２下層３２の巻き数は、前記第１コイル１２の第１下層２４と同数となるように設定されているため、前記第１上層２２及び前記第２上層３０の最外周径Ｂ１、Ｂ３が略同一となり（Ｂ１＝Ｂ３）、前記第１下層２４及び前記第２下層３２の最外周径Ｂ２、Ｂ４も略同一となる（Ｂ２＝Ｂ４）。 The number of turns of the second upper layer 30 is set to be the same as the number of turns of the first upper layer 22 of the first coil 12, and the number of turns of the second lower layer 32 is set to be the same as the number of turns of the first lower layer 24 of the first coil 12. Therefore, the outermost outer diameters B1 and B3 of the first upper layer 22 and the second upper layer 30 are substantially the same (B1 = B3), and the outermost outer diameters B2 of the first lower layer 24 and the second lower layer 32. B4 is also substantially the same (B2 = B4).

また、第４端部３４は、第２コイル１４の周方向において、第１コイル１２の第２端部２６の位置と同一となるように形成され、その上端が前記第２端部２６の下端に対して上下方向（矢印Ａ１、Ａ２方向）に重なり合うように形成されている。 Further, the fourth end portion 34 is formed so as to be the same as the position of the second end portion 26 of the first coil 12 in the circumferential direction of the second coil 14, and the upper end thereof is the lower end portion of the second end portion 26. It is formed so as to overlap with respect to the vertical direction (arrows A1 and A2 directions).

そして、第１コイル１２の第２端部２６が、第２コイル１４の第４端部３４に対して径方向内側となるように折曲され、該第４端部３４と当接した状態で、両者が重なり合った部位には、例えば、溶接等によって互いに連結されて連結部３６が形成される。 Then, the second end portion 26 of the first coil 12 is bent so as to be radially inward with respect to the fourth end portion 34 of the second coil 14, and is in contact with the fourth end portion 34. In the portion where the two overlap, for example, the connecting portion 36 is formed by being connected to each other by welding or the like.

この連結部３６は、第１コイル１２と第２コイル１４とが電気的に接続され、前記第１コイル１２の第１下層２４と前記第２コイル１４の第２下層３２との間となる該第２コイル１４の第２上層３０に臨むように設けられており、前記第１及び第２下層２４、３２の外周面２４ａ、３２ａに対して径方向内側へ窪んだ空間３８内に配置されるため、該外周面２４ａ、３２ａに対して外側へ突出することがない（図２Ｂ参照）。換言すれば、第１及び第２コイル１２、１４の最外周径が連結部３６によって径方向外側へ大きくなることがない。 The connecting portion 36 is such that the first coil 12 and the second coil 14 are electrically connected to each other and are between the first lower layer 24 of the first coil 12 and the second lower layer 32 of the second coil 14. It is provided so as to face the second upper layer 30 of the second coil 14, and is arranged in a space 38 recessed inward in the radial direction with respect to the outer peripheral surfaces 24a and 32a of the first and second lower layers 24 and 32. Therefore, it does not protrude outward with respect to the outer peripheral surfaces 24a and 32a (see FIG. 2B). In other words, the outermost outer diameters of the first and second coils 12 and 14 are not increased radially outward by the connecting portion 36.

コア１８は、例えば、磁性材料から上下方向（矢印Ａ１、Ａ２方向）に分割可能な円筒状に形成され、下部に設けられるベースコア部４０と、該ベースコア部４０の上部を覆うように設けられるカバーコア部４２とを有し、前記ベースコア部４０の中心には上方（矢印Ａ１方向）へ向かって立設した円柱状のコア軸部４４（図１参照）が形成されている。そして、コア１８の内部には、コア軸部４４の外周側に第１及び第２コイル１２、１４の巻回されたボビン１６が挿通され収納される収納空間４６を有している。 The core 18 is formed in a cylindrical shape that can be divided in the vertical direction (arrows A1 and A2 directions) from the magnetic material, and is provided so as to cover the base core portion 40 provided at the lower portion and the upper portion of the base core portion 40. A columnar core shaft portion 44 (see FIG. 1) is formed at the center of the base core portion 40, which is provided with a cover core portion 42 and is erected upward (in the direction of arrow A1). Inside the core 18, there is a storage space 46 in which the wound bobbins 16 of the first and second coils 12 and 14 are inserted and stored on the outer peripheral side of the core shaft portion 44.

また、コア１８には、収納空間４６から外側に向かって延在する一組の引出溝４８ａ、４８ｂを有し、前記引出溝４８ａ、４８ｂには、第１コイル１２の第１端部２０及び第２コイル１４の第３端部２８が挿通され外部へと引き出される。 Further, the core 18 has a set of drawer grooves 48a and 48b extending outward from the storage space 46, and the drawer grooves 48a and 48b have a first end portion 20 of the first coil 12 and a first end portion 20 and 48b. The third end 28 of the second coil 14 is inserted and pulled out to the outside.

以上のように、第１の実施の形態では、一組の第１及び第２コイル１２、１４が巻回軸Ｌの軸方向（矢印Ａ１、Ａ２方向）に沿って上下となるようにボビン１６に巻回されたリアクトル１０において、前記第１コイル１２が、巻き数が少なく小径となる第１上層２２と、該第１上層２２に対して巻き数が多く大径となる第１下層２４とから構成され、前記第１コイル１２の下方（矢印Ａ２方向）に設けられる第２コイル１４が、巻き数が少なく小径となる第２上層３０と、該第２上層３０に対して巻き数が多く大径となる第２下層３２とから構成されている。 As described above, in the first embodiment, the bobbin 16 is such that the set of the first and second coils 12 and 14 move up and down along the axial direction of the winding shaft L (arrows A1 and A2 directions). In the reactor 10 wound around, the first coil 12 has a first upper layer 22 having a smaller number of turns and a smaller diameter, and a first lower layer 24 having a larger number of turns and a larger diameter than the first upper layer 22. The second coil 14 provided below the first coil 12 (in the direction of arrow A2) has a second upper layer 30 having a smaller number of turns and a smaller diameter, and a larger number of turns than the second upper layer 30. It is composed of a second lower layer 32 having a large diameter.

そして、巻回軸Ｌの軸方向に沿って配置された第１コイル１２と第２コイル１４とを接続する際、小径の第２コイル１４の第２上層３０が、大径である第１コイル１２の第１下層２４と、同じく大径の第２コイル１４の第２下層３２との間となるように配置されている。 Then, when connecting the first coil 12 and the second coil 14 arranged along the axial direction of the winding shaft L, the second upper layer 30 of the second coil 14 having a small diameter has a large diameter. It is arranged so as to be between the first lower layer 24 of the 12 and the second lower layer 32 of the second coil 14 having the same large diameter.

そのため、第１下層２４（第１コイル１２）から取り出された第２端部２６と前記第２下層３２（第２コイル１４）から取り出された第４端部３４とを溶接等によって電気的に接続した連結部３６を、第２上層３０の外側に形成された空間３８を利用して配置している。 Therefore, the second end portion 26 taken out from the first lower layer 24 (first coil 12) and the fourth end portion 34 taken out from the second lower layer 32 (second coil 14) are electrically welded or the like. The connected connecting portion 36 is arranged by utilizing the space 38 formed on the outside of the second upper layer 30.

その結果、第１及び第２コイル１２、１４を巻回軸Ｌの軸方向に沿って積層させることで、従来技術に係るリアクトルと比較して設置面積を削減して大型化を抑制しつつ大きなインダクタンスが得られると共に、第１及び第２コイル１２、１４の最外周径である外周面２４ａ、３２ａに対して連結部３６が径方向外側（矢印Ｃ方向）へと突出することがない。そのため、第１及び第２コイル１２、１４が連結部３６によって径方向に大型化してしまうことがなく、しかも、前記連結部３６を収納するための凹部等をコア１８側へ設ける場合と比較し、リアクトル１０における製造工程及び製造コストを削減することができる。 As a result, by stacking the first and second coils 12 and 14 along the axial direction of the winding shaft L, the installation area is reduced and the size is suppressed as compared with the inductance according to the prior art. Inductance is obtained, and the connecting portion 36 does not protrude outward in the radial direction (in the direction of arrow C) with respect to the outer peripheral surfaces 24a and 32a, which are the outermost outer diameters of the first and second coils 12, 14. Therefore, the first and second coils 12 and 14 do not become large in the radial direction due to the connecting portion 36, and moreover, as compared with the case where a recess or the like for accommodating the connecting portion 36 is provided on the core 18 side. , The manufacturing process and the manufacturing cost in the reactor 10 can be reduced.

換言すれば、巻き数が多く最外周径の大きな第１コイル１２の第１下層２４、第２コイル１４の第２下層３２と、巻き数が少なく最外周径の小さな第２コイル１４における第２上層３０との外周径の差を利用して連結部３６を配置することで、該連結部３６の径方向外側（矢印Ｃ方向）への張り出しを防止することが可能となる。 In other words, the first lower layer 24 of the first coil 12 having a large number of turns and a large outermost diameter, the second lower layer 32 of the second coil 14, and the second coil 14 having a smaller number of turns and a smaller outermost diameter. By arranging the connecting portion 36 by utilizing the difference in the outer peripheral diameter from the upper layer 30, it is possible to prevent the connecting portion 36 from protruding outward in the radial direction (in the direction of arrow C).

次に、第２の実施の形態に係るリアクトル５０を図３Ａ及び図３Ｂに示す。なお、上述した第１の実施の形態に係るリアクトル１０と同一の構成要素には同一の参照符号を付して、その詳細な説明を省略する。 Next, the reactor 50 according to the second embodiment is shown in FIGS. 3A and 3B. The same components as those of the reactor 10 according to the first embodiment described above are designated by the same reference numerals, and detailed description thereof will be omitted.

この第２の実施の形態に係るリアクトル５０では、第１コイル５２を構成する第１上層５４及び第２コイル５６を構成する第２下層５８の巻き数が多く大径に形成され、第１下層６０及び第２上層６２の巻き数が前記第１上層５４及び第２下層５８に対して少なく小径に形成されており、前記第１上層５４と前記第２下層５８とが連結部６４によって接続されている点で、第１の実施の形態に係るリアクトル１０と相違している。 In the reactor 50 according to the second embodiment, the first upper layer 54 constituting the first coil 52 and the second lower layer 58 forming the second coil 56 have a large number of turns and are formed to have a large diameter, and the first lower layer is formed. The number of turns of 60 and the second upper layer 62 is smaller than that of the first upper layer 54 and the second lower layer 58, and the diameter is smaller. The first upper layer 54 and the second lower layer 58 are connected by a connecting portion 64. In that respect, it is different from the reactor 10 according to the first embodiment.

このリアクトル５０は、図３Ａ及び図３Ｂに示されるように、第１及び第２コイル５２、５６が巻回軸Ｌの軸方向（矢印Ａ１、Ａ２方向）に沿って積層されるように配置され、前記第１コイル５２は、上段となり巻き数の多い大径の第１上層（第１大径巻回部）５４と、下段となり該第１上層５４に対して巻き数が少なく小径となる第１下層（第１小径巻回部）６０とから構成される。 As shown in FIGS. 3A and 3B, the reactor 50 is arranged so that the first and second coils 52 and 56 are stacked along the axial direction of the winding shaft L (arrows A1 and A2 directions). The first coil 52 has a large diameter first upper layer (first large diameter winding portion) 54 which is an upper stage and has a large number of turns, and a first coil 52 which is a lower stage and has a smaller diameter than the first upper layer 54. It is composed of 1 lower layer (first small diameter winding portion) 60.

そして、第１下層６０の外周面から取り出された第１端部６６が、図示しないボビンを介してコア１８の引出溝４８ａから外部へと直線状に引き出されると共に、第１上層５４の外周面５４ａから取り出された第２端部６８が、第２コイル５６側（矢印Ａ２方向）へ向かうように略直角に折曲された後、下方に向かって延在して第１下層６０の下端に対して下方（矢印Ａ２方向）へと突出している。 Then, the first end portion 66 taken out from the outer peripheral surface of the first lower layer 60 is linearly drawn out from the drawer groove 48a of the core 18 via a bobbin (not shown), and the outer peripheral surface of the first upper layer 54 is formed. The second end portion 68 taken out from 54a is bent at a substantially right angle so as to face the second coil 56 side (arrow A2 direction), and then extends downward to the lower end of the first lower layer 60. On the other hand, it protrudes downward (in the direction of arrow A2).

第２コイル５６は、上段となり巻き数が少なく小径で形成された第２上層（第２小径巻回部）６２と、下段となり該第２上層６２に対して巻き数が多く大径となる第２下層（第２大径巻回部）５８とから構成される。すなわち、第１及び第２コイル５２、５６は巻回軸Ｌの軸方向（矢印Ａ１、Ａ２方向）に積層された際、巻き数が少なく小径である第１下層６０及び第２上層６２が、大径である第１上層５４と第２下層５８との間となり、且つ、軸方向（矢印Ａ１、Ａ２方向）に隣接するように配置されている。 The second coil 56 has a second upper layer (second small diameter winding portion) 62 which is an upper stage and has a small number of turns and is formed with a small diameter, and a second coil 56 which is a lower stage and has a large number of turns and a large diameter with respect to the second upper layer 62. It is composed of two lower layers (second large-diameter winding portion) 58. That is, when the first and second coils 52 and 56 are laminated in the axial direction of the winding shaft L (arrows A1 and A2 directions), the first lower layer 60 and the second upper layer 62 having a small number of turns and a small diameter are formed. It is arranged so as to be between the first upper layer 54 and the second lower layer 58, which have a large diameter, and to be adjacent to each other in the axial direction (arrows A1 and A2 directions).

そして、第２コイル５６において、第２上層６２の外周面から取り出された第３端部７０が、図示しないボビンを介してコア１８の引出溝４８ｂから外部へと直線状に引き出される。 Then, in the second coil 56, the third end portion 70 taken out from the outer peripheral surface of the second upper layer 62 is linearly pulled out from the lead-out groove 48b of the core 18 via a bobbin (not shown).

また、第２下層５８の外周面５８ａから取り出された第４端部７２が、第１コイル５２側（矢印Ａ１方向）に向かうように略直角に折曲された後、第２上層６２の上端からさらに上方（矢印Ａ１方向）へと突出するように延在し、且つ、第２コイル５６の周方向において、第１コイル５２の第２端部６８と同一位置となるように形成される。 Further, the fourth end portion 72 taken out from the outer peripheral surface 58a of the second lower layer 58 is bent at a substantially right angle toward the first coil 52 side (arrow A1 direction), and then the upper end of the second upper layer 62. It is formed so as to extend further upward (in the direction of arrow A1) and at the same position as the second end portion 68 of the first coil 52 in the circumferential direction of the second coil 56.

そして、第１コイル５２の第２端部６８は、小径に形成された第１下層６０及び第２上層６２の外周側において、第２コイル５６の第４端部７２に対して径方向内側となるように配置され径方向に互いに重なり合って当接している。この第２端部６８及び第４端部７２の重なり合った部位は、例えば、溶接等によって互いに接続されて連結部６４が形成される。 The second end portion 68 of the first coil 52 is radially inside the fourth end portion 72 of the second coil 56 on the outer peripheral side of the first lower layer 60 and the second upper layer 62 formed to have a small diameter. They are arranged so as to overlap each other in the radial direction and are in contact with each other. The overlapping portions of the second end portion 68 and the fourth end portion 72 are connected to each other by, for example, welding to form a connecting portion 64.

この連結部６４は、第１コイル５２と第２コイル５６とを電気的に接続し、大径である第１上層５４及び第２下層５８の間となる第１下層６０及び第２上層６２に臨むように設けられ、前記第１上層５４及び第２下層５８の外周面５４ａ、５８ａに対して径方向内側へ窪んだ空間７４内に配置される。そのため、最外周径となる第１コイル５２の第１上層５４の外周面５４ａ、第２コイル５６の第２下層５８の外周面５８ａに対して径方向外側（矢印Ｃ方向）へ突出することがなく、前記外周面５４ａ、５８ａの内側となる位置に好適に収納される。 The connecting portion 64 electrically connects the first coil 52 and the second coil 56 to the first lower layer 60 and the second upper layer 62 which are between the first upper layer 54 and the second lower layer 58 having a large diameter. It is provided so as to face the first upper layer 54 and the second lower layer 58, and is arranged in a space 74 recessed inward in the radial direction with respect to the outer peripheral surfaces 54a and 58a. Therefore, it may project radially outward (in the arrow C direction) with respect to the outer peripheral surface 54a of the first upper layer 54 of the first coil 52 and the outer peripheral surface 58a of the second lower layer 58 of the second coil 56, which are the outermost outer diameters. It is preferably stored in a position inside the outer peripheral surfaces 54a and 58a.

以上のように、第２の実施の形態では、一組の第１及び第２コイル５２、５６が巻回軸Ｌの軸方向に沿って上下となるようにボビン（図示せず）に巻回されたリアクトル５０において、大径となる第１上層５４及び第２下層５８を、それぞれ第１コイル５２の上段、第２コイル５６の下段とし、小径となる第１下層６０及び第２上層６２を、前記第１上層５４と前記第２下層５８との間に配置している。 As described above, in the second embodiment, a set of the first and second coils 52 and 56 are wound around the bobbin (not shown) so as to be up and down along the axial direction of the winding shaft L. In the reactor 50, the first upper layer 54 and the second lower layer 58 having a large diameter are set as the upper stage of the first coil 52 and the lower stage of the second coil 56, respectively, and the first lower layer 60 and the second upper layer 62 having a smaller diameter are used. , Is arranged between the first upper layer 54 and the second lower layer 58.

これにより、第１及び第２コイル５２、５６を巻回軸Ｌの軸方向に沿って積層させることで、従来技術に係るリアクトルと比較して設置面積を削減して大型化を抑制しつつ大きなインダクタンスを得ることができると共に、第１及び第２コイル５２、５６を電気的に接続する連結部６４が、前記第１及び第２コイル５２、５６の外周面５４ａ、５８ａに対して径方向外側（矢印Ｃ方向）へと突出することがない。 As a result, the first and second coils 52 and 56 are laminated along the axial direction of the winding shaft L, thereby reducing the installation area and suppressing the increase in size as compared with the inductance according to the prior art. Inductance can be obtained, and the connecting portion 64 that electrically connects the first and second coils 52 and 56 is radially outer with respect to the outer peripheral surfaces 54a and 58a of the first and second coils 52 and 56. It does not protrude in the (arrow C direction).

そのため、第１及び第２コイル５２、５６が連結部６４によって径方向に大型化してしまうことがなく、しかも、前記連結部６４を収納するための凹部等をコア１８側へ設けた場合と比較し、リアクトル５０における製造工程及び製造コストの削減を図ることが可能となる。 Therefore, the first and second coils 52 and 56 do not become large in the radial direction due to the connecting portion 64, and compared with the case where a recess or the like for accommodating the connecting portion 64 is provided on the core 18 side. However, it is possible to reduce the manufacturing process and manufacturing cost of the reactor 50.

また、リアクトル５０の軸方向（矢印Ａ１、Ａ２方向）において、第１上層５４と第２下層５８との間にその外周面５４ａ、５８ａに対して径方向内側となる空間７４を確保することができるため、大径である第１コイル５２の第１上層５４と第２コイル５６の第２下層５８とを接続する連結部６４を、前記空間７４内に容易に配置することができ、その連結作業が容易となる。 Further, in the axial direction of the reactor 50 (arrows A1 and A2 directions), it is possible to secure a space 74 between the first upper layer 54 and the second lower layer 58 in the radial direction with respect to the outer peripheral surfaces 54a and 58a. Therefore, the connecting portion 64 for connecting the first upper layer 54 of the first coil 52 having a large diameter and the second lower layer 58 of the second coil 56 can be easily arranged in the space 74, and the connecting portion 64 can be easily arranged. Work becomes easy.

さらに、小径である第１コイル５２の第１下層６０、第２コイル５６の第２上層６２とが、リアクトル５０の軸方向（矢印Ａ１、Ａ２方向）に沿って隣接して配置されているため、第１の実施の形態に係るリアクトル１０と比較し、径方向内側の空間７４を大きく確保することが可能となる。そのため、第１コイル５２と第２コイル５６との連結部６４をより一層容易に配置して収納することが可能となる。 Further, since the first lower layer 60 of the first coil 52 and the second upper layer 62 of the second coil 56, which have a small diameter, are arranged adjacent to each other along the axial direction of the reactor 50 (arrows A1 and A2 directions). As compared with the reactor 10 according to the first embodiment, it is possible to secure a large space 74 inside in the radial direction. Therefore, the connecting portion 64 between the first coil 52 and the second coil 56 can be arranged and stored more easily.

次に、第３の実施の形態に係るリアクトル８０を図４Ａ及び図４Ｂに示す。なお、上述した第１の実施の形態に係るリアクトル１０と同一の構成要素には同一の参照符号を付して、その詳細な説明を省略する。 Next, the reactor 80 according to the third embodiment is shown in FIGS. 4A and 4B. The same components as those of the reactor 10 according to the first embodiment described above are designated by the same reference numerals, and detailed description thereof will be omitted.

この第３の実施の形態に係るリアクトル８０では、第１コイル８２において巻き数が多い大径の第１下層８４と、第２コイル８６において巻き数が少ない小径の第２上層８８とが連結部９０によって接続されている点で、第１の実施の形態に係るリアクトル１０と相違している。 In the reactor 80 according to the third embodiment, the large-diameter first lower layer 84 having a large number of turns in the first coil 82 and the small-diameter second upper layer 88 having a small number of turns in the second coil 86 are connected to each other. It differs from the reactor 10 according to the first embodiment in that it is connected by 90.

このリアクトル８０は、図４Ａ及び図４Ｂに示されるように、第１及び第２コイル８２、８６が巻回軸Ｌの軸方向（矢印Ａ１、Ａ２方向）に沿って積層されるように配置され、前記第１コイル８２は、上段となり巻き数が少なく小径となる第１上層（第１小径巻回部）９２と、下段となり該第１上層９２に対して巻き数が多く大径となる第１下層（第１大径巻回部）８４とから構成される。 As shown in FIGS. 4A and 4B, the reactor 80 is arranged so that the first and second coils 82 and 86 are stacked along the axial direction of the winding shaft L (arrows A1 and A2 directions). The first coil 82 has a first upper layer (first small diameter winding portion) 92 which is an upper stage and has a small number of turns and a small diameter, and a first coil 82 which is a lower stage and has a large number of turns and a large diameter with respect to the first upper layer 92. It is composed of 1 lower layer (first large-diameter winding portion) 84.

そして、第１上層９２の外周面から取り出された第１端部９４が、図示しないボビンを介してコア１８の引出溝４８ａから外部へと直線状に引き出されると共に、第１下層８４の外周面８４ａから取り出された第２端部９６が、第２コイル８６側（矢印Ａ２方向）へ向かうように略直角に折曲された後、下方に向かって延在して第１下層８４の下端に対して下方へ突出している。 Then, the first end portion 94 taken out from the outer peripheral surface of the first upper layer 92 is linearly drawn out from the drawer groove 48a of the core 18 via a bobbin (not shown), and the outer peripheral surface of the first lower layer 84 is formed. The second end 96 taken out from 84a is bent at a substantially right angle toward the second coil 86 side (arrow A2 direction), and then extends downward to the lower end of the first lower layer 84. On the other hand, it protrudes downward.

第２コイル８６は、上段となり巻き数が少なく小径となる第２上層（第２小径巻回部）８８と、下段となり該第２上層８８に対して巻き数が多く大径となる第２下層（第２大径巻回部）９８とから構成される。 The second coil 86 has a second upper layer (second small diameter winding portion) 88 which is an upper stage and has a small number of turns and a small diameter, and a second lower layer which is a lower stage and has a large number of turns and a large diameter with respect to the second upper layer 88. (2nd large diameter winding part) 98.

すなわち、第１及び第２コイル８２、８６は巻回軸Ｌの軸方向（矢印Ａ１、Ａ２方向）に積層された際、巻き数が少なく小径の第１上層９２及び第２上層８８と、大径の第１下層８４及び第２下層９８とが前記軸方向に沿って交互となるように配置されている。 That is, when the first and second coils 82 and 86 are laminated in the axial direction of the winding shaft L (arrows A1 and A2 directions), the number of turns is small and the diameter is large as the first upper layer 92 and the second upper layer 88. The first lower layer 84 and the second lower layer 98 having a diameter are arranged so as to alternate along the axial direction.

そして、第２下層９８の外周面９８ａから取り出された第３端部１００が、図示しないボビンを介してコア１８の引出溝４８ｂから外部へと直線状に引き出される。 Then, the third end portion 100 taken out from the outer peripheral surface 98a of the second lower layer 98 is linearly pulled out from the pull-out groove 48b of the core 18 via a bobbin (not shown).

また、第２上層８８の外周面から取り出された第４端部１０２が、径方向外側（矢印Ｃ方向）に向けて折曲された後、第２コイル８６の巻回方向に沿って延在するように形成される。そして、第１コイル８２の第２端部９６と略直交するように交差し、その径方向内側に配置されることで互いに当接した状態で径方向に互いに重なり合う。そして、第４端部１０２と第２端部９６とが重なり合った部位には、例えば、溶接等によって互いに接続されて連結部９０が形成される。 Further, the fourth end 102 taken out from the outer peripheral surface of the second upper layer 88 is bent outward in the radial direction (direction of arrow C) and then extends along the winding direction of the second coil 86. Formed to do. Then, they intersect with the second end 96 of the first coil 82 so as to be substantially orthogonal to each other, and are arranged inside the first coil 82 in the radial direction so as to be in contact with each other and overlap each other in the radial direction. Then, at the portion where the fourth end portion 102 and the second end portion 96 overlap, for example, they are connected to each other by welding or the like to form a connecting portion 90.

この連結部９０は、第１コイル８２と第２コイル８６とを電気的に接続し、大径である第１コイル８２の第１下層８４と第２コイル８６の第２下層９８との間となる第２上層８８に臨むように設けられ、前記第１下層８４及び前記第２下層９８の外周面８４ａ、９８ａに対して径方向内側へ窪んだ空間１０４内に配置される。そのため、最外周径となる第１コイル８２の第１下層８４の外周面８４ａ、第２コイル８６の第２下層９８の外周面９８ａに対して連結部９０が径方向外側（矢印Ｃ方向）へ突出することがなく、前記外周面８４ａ、９８ａの内側（径方向内側）となる位置に好適に収納される（図４Ｂ参照）。 The connecting portion 90 electrically connects the first coil 82 and the second coil 86, and between the first lower layer 84 of the first coil 82 and the second lower layer 98 of the second coil 86, which have a large diameter. It is provided so as to face the second upper layer 88, and is arranged in a space 104 recessed inward in the radial direction with respect to the outer peripheral surfaces 84a and 98a of the first lower layer 84 and the second lower layer 98. Therefore, the connecting portion 90 is radially outward (in the direction of arrow C) with respect to the outer peripheral surface 84a of the first lower layer 84 of the first coil 82 and the outer peripheral surface 98a of the second lower layer 98 of the second coil 86, which are the outermost outer diameters. It is preferably stored in a position that does not protrude and is inside (diameterally inside) the outer peripheral surfaces 84a and 98a (see FIG. 4B).

以上のように、第３の実施の形態では、一組の第１及び第２コイル８２、８６が巻回軸Ｌの軸方向に沿って上下となるようにボビン（図示せず）に巻回されたリアクトル８０において、大径となる第１コイル８２の第１下層８４、第２コイル８６の第２下層９８との間に、小径となる第２コイル８６の第２上層８８を配置している。そして、第１下層８４から取り出された第２端部９６と第２上層８８から取り出された第４端部１０２とを、前記第２上層８８の外周側、且つ、第１下層８４及び第２下層９８の外周面８４ａ、９８ａに対して径方向内側となる空間１０４内で連結することで、その連結部９０を前記空間１０４内に好適に収納することができる。 As described above, in the third embodiment, a set of the first and second coils 82 and 86 are wound around the bobbin (not shown) so as to be up and down along the axial direction of the winding shaft L. In the reactor 80, the second upper layer 88 of the second coil 86 having a smaller diameter is arranged between the first lower layer 84 of the first coil 82 having a larger diameter and the second lower layer 98 of the second coil 86 having a smaller diameter. There is. Then, the second end portion 96 taken out from the first lower layer 84 and the fourth end portion 102 taken out from the second upper layer 88 are placed on the outer peripheral side of the second upper layer 88, and the first lower layer 84 and the second. By connecting the lower layer 98 to the outer peripheral surfaces 84a and 98a in the space 104 which is radially inside, the connecting portion 90 can be suitably stored in the space 104.

これにより、第１及び第２コイル８２、８６を巻回軸Ｌの軸方向に沿って積層させることで、従来技術に係るリアクトルと比較して設置面積を削減して大型化を抑制しつつ大きなインダクタンスを得ることができると共に、第１及び第２コイル８２、８６を電気的に接続する連結部９０が、前記第１及び第２コイル８２、８６の外周面８４ａ、９８ａから径方向外側（矢印Ｃ方向）へと突出することがない。 As a result, the first and second coils 82 and 86 are laminated along the axial direction of the winding shaft L, thereby reducing the installation area and suppressing the increase in size as compared with the inductance according to the prior art. Inductance can be obtained, and the connecting portion 90 that electrically connects the first and second coils 82 and 86 is radially outward from the outer peripheral surfaces 84a and 98a of the first and second coils 82 and 86 (arrows). It does not protrude in the C direction).

そのため、第１及び第２コイル８２、８６が連結部９０によって径方向に大型化してしまうことがなく、しかも、前記連結部９０を収納するための凹部等をコア１８側へ設けた場合と比較し、リアクトル８０における製造工程及び製造コストの削減を図ることができる。 Therefore, the first and second coils 82 and 86 do not become large in the radial direction due to the connecting portion 90, and compared with the case where a recess or the like for accommodating the connecting portion 90 is provided on the core 18 side. However, the manufacturing process and manufacturing cost of the reactor 80 can be reduced.

また、連結部９０が第１及び第２コイル８２、８６の最外周径となる外周面８４ａ、９８ａよりも径方向外側（矢印Ｃ方向）へ突出してしまうことがなく、しかも、小径である第２上層８８に連結部９０を設けることで、その第４端部１０２を第１コイル８２の第２端部９６と連結するために径方向外側（矢印Ｃ方向）へ折曲させた場合でも、前記外周面８４ａ、９８ａの外側（径方向外側）に突出することがない。そのため、リアクトル８０の大型化を回避することが可能となる。 Further, the connecting portion 90 does not protrude radially outward (in the direction of arrow C) from the outer peripheral surfaces 84a and 98a, which are the outermost outer diameters of the first and second coils 82 and 86, and has a smaller diameter. 2 By providing the connecting portion 90 in the upper layer 88, even when the fourth end portion 102 is bent radially outward (in the direction of arrow C) in order to connect with the second end portion 96 of the first coil 82. It does not protrude to the outside (diameterally outside) of the outer peripheral surfaces 84a and 98a. Therefore, it is possible to avoid an increase in the size of the reactor 80.

次に、第４の実施の形態に係るリアクトル１１０を図５Ａ及び図５Ｂに示す。なお、上述した第２の実施の形態に係るリアクトル５０と同一の構成要素には同一の参照符号を付して、その詳細な説明を省略する。 Next, the reactor 110 according to the fourth embodiment is shown in FIGS. 5A and 5B. The same components as those of the reactor 50 according to the second embodiment described above are designated by the same reference numerals, and detailed description thereof will be omitted.

この第４の実施の形態に係るリアクトル１１０では、第１コイル１１２において巻き数が少ない小径の第１下層１１４と、第２コイル１１６において巻き数が少なく該第１下層１１４と隣接した小径の第２上層１１８とを連結部１２０によって互いに接続している点で、第２の実施の形態に係るリアクトル５０と相違している。 In the reactor 110 according to the fourth embodiment, the first lower layer 114 having a small number of turns in the first coil 112 and the small diameter first lower layer 114 having a small number of turns in the second coil 116 and adjacent to the first lower layer 114. It differs from the reactor 50 according to the second embodiment in that the upper layer 118 and the upper layer 118 are connected to each other by the connecting portion 120.

このリアクトル１１０は、図５Ａ及び図５Ｂに示されるように、第１及び第２コイル１１２、１１６が巻回軸Ｌの軸方向（矢印Ａ１、Ａ２方向）に沿って積層されるように配置され、前記第１コイル１１２を構成する大径の第１上層（第１大径巻回部）１２２から第１端部１２４が取り出されると共に、該第１上層１２２に対して巻き数が少なく小径な第１下層（第１小径巻回部）１１４の外周面から第２端部１２６が取り出される。 As shown in FIGS. 5A and 5B, the reactor 110 is arranged so that the first and second coils 112 and 116 are stacked along the axial direction of the winding shaft L (arrows A1 and A2 directions). The first end portion 124 is taken out from the large-diameter first upper layer (first large-diameter winding portion) 122 constituting the first coil 112, and the number of turns is smaller than that of the first upper layer 122 and the diameter is smaller. The second end portion 126 is taken out from the outer peripheral surface of the first lower layer (first small diameter winding portion) 114.

この第２端部１２６は、径方向外側（矢印Ｃ方向）に向かって折曲された後、第１コイル１１２の巻回方向に沿って延在すると共に、第２コイル１１６側（矢印Ａ２方向）へ向かうように略直角に折曲される。なお、第２端部１２６は、図５Ｂに示されるように、第１コイル１１２の最外周径である第１上層１２２の外周面１２２ａに対して外側（径方向外側）へ突出することがないように形成される。そして、第２端部１２６の先端は、下方に向かって延在すると共に第１下層１１４の下端に対して下方（矢印Ａ２方向）へと突出している。 The second end portion 126 is bent outward in the radial direction (direction of arrow C) and then extends along the winding direction of the first coil 112 and is on the side of the second coil 116 (direction of arrow A2). ) Is bent at a right angle. As shown in FIG. 5B, the second end portion 126 does not protrude outward (diameterally outward) with respect to the outer peripheral surface 122a of the first upper layer 122, which is the outermost outer diameter of the first coil 112. Is formed like this. The tip of the second end portion 126 extends downward and protrudes downward (in the direction of arrow A2) with respect to the lower end of the first lower layer 114.

一方、第２コイル１１６を構成する大径の第２下層（第２大径巻回部）１２８の外周面１２８ａから第３端部１３０が取り出されると共に、該第２下層１２８に対して上段となり巻き数が少なく小径となる第２上層（第２小径巻回部）１１８の外周面から第４端部１３２が取り出される。 On the other hand, the third end portion 130 is taken out from the outer peripheral surface 128a of the large-diameter second lower layer (second large-diameter winding portion) 128 constituting the second coil 116, and is an upper stage with respect to the second lower layer 128. The fourth end 132 is taken out from the outer peripheral surface of the second upper layer (second small diameter winding portion) 118 having a small number of turns and a small diameter.

すなわち、第１及び第２コイル１１２、１１６は巻回軸Ｌの軸方向（矢印Ａ１、Ａ２方向）に積層された際、巻き数が少なく小径の第１下層１１４及び第２上層１１８が、大径である第１上層１２２と第２下層１２８との間となり、且つ、軸方向に隣接するように配置されている。 That is, when the first and second coils 112 and 116 are laminated in the axial direction of the winding shaft L (arrows A1 and A2 directions), the first lower layer 114 and the second upper layer 118 having a small number of turns and a small diameter are large. The first upper layer 122 and the second lower layer 128, which have a diameter, are arranged so as to be adjacent to each other in the axial direction.

そして、第２上層１１８の第４端部１３２は、径方向外側（矢印Ｃ方向）に向かって折曲された後、第２コイル１１６の巻回方向に沿って延在すると共に、第１コイル１１２側（矢印Ａ１方向）へ向かうように略直角に折曲される。なお、第４端部１３２は、第２コイル１１６の最外周径である第２下層１２８の外周面１２８ａに対して外側へ突出することがないように形成される。 Then, the fourth end 132 of the second upper layer 118 is bent outward in the radial direction (direction of arrow C) and then extends along the winding direction of the second coil 116 and the first coil. It is bent at a substantially right angle toward the 112 side (direction of arrow A1). The fourth end 132 is formed so as not to protrude outward with respect to the outer peripheral surface 128a of the second lower layer 128, which is the outermost diameter of the second coil 116.

また、第４端部１３２の先端は上方に向かって延在し、図５Ｂに示されるように、第２端部１２６に対して径方向内側となるように重なり合って当接している。 Further, the tip of the fourth end portion 132 extends upward and, as shown in FIG. 5B, is in contact with the second end portion 126 so as to be radially inward.

上述したように、第４端部１３２と第２端部１２６とが重なり合った部位は、例えば、溶接等によって互いに接続されて連結部１２０が形成される。この連結部１２０は、第１コイル１１２と第２コイル１１６とを電気的に接続し、大径である第１コイル１１２の第１上層１２２と第２コイル１１６の第２下層１２８との間となり、第１下層１１４及び第２上層１１８に臨むように設けられ、前記第１上層１２２及び前記第２下層１２８の外周面１２２ａ、１２８ａに対して径方向内側へ窪んだ空間１３４内に配置される。 As described above, the portions where the fourth end portion 132 and the second end portion 126 overlap are connected to each other by welding or the like to form the connecting portion 120. The connecting portion 120 electrically connects the first coil 112 and the second coil 116, and is between the first upper layer 122 of the first coil 112 and the second lower layer 128 of the second coil 116, which have a large diameter. , The first lower layer 114 and the second upper layer 118 are provided so as to face each other, and are arranged in a space 134 recessed inward in the radial direction with respect to the outer peripheral surfaces 122a and 128a of the first upper layer 122 and the second lower layer 128. ..

そのため、最外周径となる第１コイル１１２の第１上層１２２の外周面１２２ａ、第２コイル１１６の第２下層１２８の外周面１２８ａに対して連結部１２０が径方向外側（矢印Ｃ方向）へ突出することがなく、前記外周面１２２ａ、１２８ａの内側（径方向内側）となる位置に好適に収納される。 Therefore, the connecting portion 120 is radially outward (in the direction of arrow C) with respect to the outer peripheral surface 122a of the first upper layer 122 of the first coil 112 and the outer peripheral surface 128a of the second lower layer 128 of the second coil 116, which are the outermost outer diameters. It is preferably stored in a position that does not protrude and is inside (diameterally inside) the outer peripheral surfaces 122a and 128a.

以上のように、第４の実施の形態では、一組の第１及び第２コイル１１２、１１６が巻回軸Ｌの軸方向に沿って上下となるようにボビン（図示せず）に巻回されたリアクトル１１０において、大径となる第１コイル１１２の第１上層１２２と、同じく大径となる第２コイル１１６の第２下層１２８との間に、小径となる第１コイル１１２の第１下層１１４及び第２コイル１１６の第２上層１１８を配置している。そして、第１下層１１４から取り出された第２端部１２６と第２上層１１８から取り出された第４端部１３２とを、前記第１下層１１４及び前記第２上層１１８の外周側、且つ、第１上層１２２及び第２下層１２８の外周面１２２ａ、１２８ａに対して径方向内側となる空間１３４内で連結することで、その連結部１２０を前記空間１３４内に好適に収納することができる。 As described above, in the fourth embodiment, a set of the first and second coils 112 and 116 are wound around the bobbin (not shown) so as to be up and down along the axial direction of the winding shaft L. In the reactor 110, the first upper layer 122 of the first coil 112 having a large diameter and the second lower layer 128 of the second coil 116 having a large diameter have a small diameter. The lower layer 114 and the second upper layer 118 of the second coil 116 are arranged. Then, the second end portion 126 taken out from the first lower layer 114 and the fourth end portion 132 taken out from the second upper layer 118 are placed on the outer peripheral side of the first lower layer 114 and the second upper layer 118, and the second one. By connecting the upper layer 122 and the second lower layer 128 with respect to the outer peripheral surfaces 122a and 128a in the space 134 that is radially inside, the connecting portion 120 can be suitably stored in the space 134.

これにより、第１及び第２コイル１１２、１１６を巻回軸Ｌの軸方向に沿って積層させることで、従来技術に係るリアクトルと比較して設置面積を削減して大型化を抑制しつつ大きなインダクタンスを得ることができると共に、第１及び第２コイル１１２、１１６を電気的に接続する連結部１２０が、前記第１及び第２コイル１１２、１１６の外周面１２２ａ、１２８ａに対して径方向外側（矢印Ｃ方向）へと突出することがない。 As a result, the first and second coils 112 and 116 are laminated along the axial direction of the winding shaft L, thereby reducing the installation area and suppressing the increase in size as compared with the inductance according to the prior art. Inductance can be obtained, and the connecting portion 120 that electrically connects the first and second coils 112 and 116 is radially outer with respect to the outer peripheral surfaces 122a and 128a of the first and second coils 112 and 116. It does not protrude in the (arrow C direction).

そのため、第１及び第２コイル１１２、１１６が連結部１２０によって径方向に大型化してしまうことがなく、しかも、前記連結部１２０を収納するための凹部等をコア１８側へ設けた場合と比較し、リアクトル１１０における製造工程及び製造コストの削減が可能となる。 Therefore, the first and second coils 112 and 116 do not become large in the radial direction due to the connecting portion 120, and are compared with the case where a recess or the like for accommodating the connecting portion 120 is provided on the core 18 side. However, the manufacturing process and manufacturing cost of the reactor 110 can be reduced.

また、連結部１２０が第１及び第２コイル１１２、１１６の最外周径となる外周面１２２ａ、１２８ａよりも径方向外側（矢印Ｃ方向）へ突出してしまうことがなく、しかも、小径である第１下層１１４及び第２上層１１８の外周側に連結部１２０を設けることで、第２端部１２６及び第４端部１３２を互いに接続するために径方向外側に折曲させた場合でも、前記外周面１２２ａ、１２８ａの外側（径方向外側）へ突出してしまうことがない。そのため、リアクトル１１０の大型化を回避することが可能となる。 Further, the connecting portion 120 does not protrude radially outward (in the direction of arrow C) from the outer peripheral surfaces 122a and 128a, which are the outermost outer diameters of the first and second coils 112 and 116, and has a small diameter. By providing the connecting portion 120 on the outer peripheral side of the lower layer 114 and the second upper layer 118, even when the second end portion 126 and the fourth end portion 132 are bent outward in the radial direction in order to connect to each other, the outer peripheral portion is described. It does not protrude to the outside (diameterally outside) of the surfaces 122a and 128a. Therefore, it is possible to avoid an increase in the size of the reactor 110.

なお、本発明に係るリアクトルは、上述の実施の形態に限らず、本発明の要旨を逸脱することなく、種々の構成を採り得ることはもちろんである。 It should be noted that the reactor according to the present invention is not limited to the above-described embodiment, and of course, various configurations can be adopted without departing from the gist of the present invention.

１０、５０、８０、１１０…リアクトル
１２、５２、８２、１１２…第１コイル
１４、５６、８６、１１６…第２コイル
２２、５４、９２、１２２…第１上層
２４、６０、８４、１１４…第１下層
３０、６２、８８、１１８…第２上層
３２、５８、９８、１２８…第２下層
３６、６４、９０、１２０…連結部
３８、７４、１０４、１３４…空間 10, 50, 80, 110 ... Reactors 12, 52, 82, 112 ... First coils 14, 56, 86, 116 ... Second coils 22, 54, 92, 122 ... First upper layers 24, 60, 84, 114 ... 1st lower layer 30, 62, 88, 118 ... 2nd upper layer 32, 58, 98, 128 ... 2nd lower layer 36, 64, 90, 120 ... Connecting portion 38, 74, 104, 134 ... Space

Claims (3)

α巻きで上下２層に巻回された第１コイルと、α巻きで上下２層に巻回された第２コイルとを備えたリアクトルにおいて、
前記第１コイルは、一方の層を構成し巻き数の少ない第１小径巻回部と、他方の層を構成し前記第１小径巻回部に対して前記巻き数の多い第１大径巻回部とを有し、
前記第２コイルは、一方の層を構成し前記巻き数の少ない第２小径巻回部と、他方の層を構成し前記第２小径巻回部に対して前記巻き数の多い第２大径巻回部とを有し、
前記第１コイルと前記第２コイルとが巻回軸の軸方向に沿って同軸状に配置され、前記第１小径巻回部及び前記第２小径巻回部の少なくとも一方が、前記第１大径巻回部及び前記第２大径巻回部の間となるように配置されると共に、前記第１コイルと前記第２コイルとを電気的に接続する連結部が、前記第１小径巻回部及び前記第２小径巻回部の少なくとも一方の外周側に配置される、リアクトル。 In a reactor provided with a first coil wound in two upper and lower layers by α winding and a second coil wound in two upper and lower layers by α winding.
The first coil has a first small-diameter winding portion that constitutes one layer and has a small number of turns, and a first large-diameter winding portion that constitutes the other layer and has a large number of turns with respect to the first small-diameter winding portion. Has a coil and
The second coil constitutes one layer and has a second small diameter winding portion having a small number of turns, and the second coil has a second large diameter having a large number of turns with respect to the second small diameter winding portion forming the other layer. Has a winding part and
The first coil and the second coil are arranged coaxially along the axial direction of the winding shaft, and at least one of the first small-diameter winding portion and the second small-diameter winding portion is the first large. The connecting portion that is arranged between the diameter winding portion and the second large diameter winding portion and electrically connects the first coil and the second coil is the first small diameter winding portion. A reactor arranged on the outer peripheral side of at least one of the portion and the second small-diameter winding portion. 請求項１記載のリアクトルにおいて、
前記連結部が、前記第１大径巻回部と前記第２大径巻回部を互いに連結する、リアクトル。 In the reactor according to claim 1,
A reactor in which the connecting portion connects the first large-diameter winding portion and the second large-diameter winding portion to each other. 請求項１記載のリアクトルにおいて、
前記連結部は、前記第１小径巻回部及び前記第２小径巻回部の少なくとも一方に設けられ、前記連結部を有した前記第１小径巻回部及び前記第２小径巻回部の少なくとも一方が径方向外側へ屈曲して形成される、リアクトル。 In the reactor according to claim 1,
The connecting portion is provided on at least one of the first small-diameter winding portion and the second small-diameter winding portion, and at least one of the first small-diameter winding portion and the second small-diameter winding portion having the connecting portion. A reactor formed by bending one side outward in the radial direction.

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