JP2005072198A - Method and device for reducing noise of reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problem that the conventional method and device for reducing noise reactor can not reduce the noise of a on-vehicle reactor to a required noise level and, in addition, the reactor becomes large in size as a whole and unsuitable to be loaded in a vehicle and is difficult to be mass-produced due to its structure. <P>SOLUTION: The noise of the reactor constituted of a coil 6 and a core 5 is reduced by housing the reactor in a highly heat-conductive case 2 and, after a sealing resin 8 is packed and cured in the internal space of the case 2 housing the reactor, closing the opening 2a of the case 2 with a lid body 7 constituted of a foamed member having a semicontinuous and semiindependent bubble structure. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a reactor noise reduction method and apparatus mounted on a fuel cell vehicle or a hybrid vehicle.

Generally, reactors used in vehicles such as fuel cell vehicles and hybrid vehicles have a large current / high voltage specification, and therefore tend to generate large noise. In particular, since the generated frequency is a high frequency in the range of approximately 5 kHz to 20 kHz, it is required to suppress noise.
Therefore, a technique for reducing noise generated from the reactor has been devised.
For example, Patent Document 1 discloses an adhesive having an adhesive strength of 100 kgf / cm 2 or more, such as adhesion of abutting portions between core constituent members, adhesion fixation between steel plates laminated by varnish impregnation in the core, and fixation between a core and a coil. The technique which aims at noise reduction by performing by adhesion | attachment by is disclosed.
Moreover, as shown in Patent Document 2, a technique for preventing noise by attaching a reinforcing stay or a damping steel plate to a tank that stores a reactor is disclosed.

Japanese Patent Laid-Open No. 08-111322

Japanese Patent Publication No. 03-66805

However, since the reactor for a fuel cell vehicle or a hybrid vehicle generates noise that greatly exceeds the noise level of ordinary consumer products, the core component member is not provided as in the technique described in Patent Document 1 described above. Noise cannot be reduced to the required noise level only by structural measures such as strengthening the restraining force between the butted portion, the laminated steel plates of the core, and between the core and the coil with an adhesive.
In addition, in the case of the structure of Patent Document 2, since the tank itself is enlarged, a reinforcing stay and a damping steel plate are attached, so that the overall size is increased and it is not suitable for in-vehicle use, and the structure is mass-produced. It was difficult.

  Therefore, the present invention provides a noise reduction method and apparatus that can suppress the noise of a reactor for a fuel cell vehicle or a hybrid vehicle in a curable manner, and can achieve downsizing and improvement in mass productivity.

The reactor noise reduction method and apparatus of the present invention for solving the above-described problems have the following features.
That is, as described in claim 1, a reactor composed of a coil and a core is accommodated in a high heat conduction case, and a space in the high heat conduction case in which the reactor is accommodated is filled with a sealing resin and cured. The noise of the reactor is reduced by closing the opening of the conductive case with a lid formed of a foam member having a semi-continuous / single-bubble structure.
In this way, noise can be reduced with a simple structure by simply placing a lid made of foam with a semi-semi-single foam structure in the opening of the case, so noise reduction devices can be easily mass-produced at low cost. Is possible.
Moreover, since the reactor does not increase in size, noise suppression can be realized without impairing the need for downsizing required for a vehicle-mounted reactor.

According to a second aspect of the present invention, the foam member is disposed in the opening of the high heat conduction case in a compressed state.
As a result, the lid body expands in a direction orthogonal to the compression direction, the gap between the case and the lid body disappears, and the lid body comes into close contact with the surface of the sealing resin.
Therefore, noise can be prevented from leaking outside through the gap between the case and the lid, and noise can be efficiently suppressed.

According to a third aspect of the present invention, there is provided a reactor noise reduction device comprising: a high heat conduction case that houses a reactor composed of a coil and a core; and a sealing resin that fills a space in the high heat conduction case that contains the reactor. And a lid formed of a foamed member having a half-single-half-single-bubble structure that closes the opening of the high heat conduction case.
As a result, noise can be reduced with a simple structure by simply placing a lid made of foam with a semi-semi-single-cell foam structure at the opening of the case, making it possible to easily mass-produce noise reduction devices at low cost. It is.
Moreover, since the reactor does not increase in size, noise suppression can be realized without impairing the need for downsizing required for a vehicle-mounted reactor.

According to a fourth aspect of the present invention, the foam member of the noise reduction device is disposed in the opening of the high heat conduction case in a compressed state.
As a result, the lid body expands in a direction orthogonal to the compression direction, the gap between the case and the lid body disappears, and the lid body comes into close contact with the surface of the sealing resin.
Therefore, noise can be prevented from leaking outside through the gap between the case and the lid, and noise can be efficiently suppressed.

According to the present invention, noise can be reduced with a simple structure, and a noise reduction device can be easily mass-produced at low cost.
In addition, efficient noise suppression can be realized without impairing the need for downsizing required for in-vehicle reactors.

Next, modes for carrying out the present invention will be described with reference to the accompanying drawings.
1 to 3 show a first embodiment of a reactor noise reduction apparatus according to the present invention. The noise reduction device 1 includes a case 2 that houses a reactor composed of a core 5 and a coil 6, a sealing resin 8 that fills a space inside the case 2 that houses the reactor, and an opening 2 a of the case 2. And a lid 7 for closing.

The case 2 is formed in a box shape having an upper opening, and is installed on the heat sink 9.
Further, one surface of the reactor (core 5 and coil 6) accommodated in the case 2 is urged by the spring 3 and positioned in contact with one side surface of the case 2.

The sealing resin 8 is composed of an epoxy resin, a urethane-based resin, or the like, and is cured after being filled into the space in the case 2 by potting or the like in a paste-like uncured state. The core 5 and the coil 6 are completely covered with the sealing resin 8 except for the terminal 6 a of the coil 6.
The case 2 is configured by a member having good thermal conductivity, and is configured such that heat generated from the core 5 and the coil 6 and transmitted to the case 2 through the sealing resin 8 quickly escapes to the heat sink 9. ing.

The lid 7 is made of a foam having a semi-continuous and semi-foam structure. As this foam, for example, EPDM (Ethylene Propylene Diene Terpolymer) is used.
The lid 7 is disposed in the opening 2a of the case 2 in a state where it is in contact with the upper surface of the sealing resin 8 or a slight gap is provided, and closes the opening 2a.
Here, the foam having a semi-continuous / single-bubble structure refers to a foam in which open cells and closed cells are mixed, and in this embodiment, for example, approximately 50% of open cells and closed cells are present. The foam is used.

  In the case of this embodiment, for example, the lid 7 is fixed to the upper surface of the sealing resin 8 with an adhesive, an adhesive tape, or the like, and the thickness of the lid 7 is 10 mm or more.

  As described above, the noise reduction device 1 stores the reactor constituted by the coil 6 and the core 5 in the case 2 with high thermal conductivity, and fills the space in the case 2 storing the reactor with the sealing resin 8. After being cured, the opening 2a of the case 2 is configured by closing with a lid body 7 formed of a foam member having a half-half-half-cell foam structure.

  Here, reactors mounted on fuel cell vehicles and hybrid electric vehicles are driven by large currents and high voltages, so the attractive force generated by ripple currents is also large, which is larger and harsh than normal consumer products.・ Make noise.

  In the case where the core 5 and the coil 6 are accommodated in the case 2 and only the sealing resin 8 is filled, vibrations having a frequency up to about 5 kHz among the vibrations generated from the reactor are transmitted in the horizontal direction through the sealing resin 8. The side surface of the case 2 is vibrated, thereby generating noise.

  In addition, vibration with a frequency of about 10 kHz proceeds in the sealing resin 8 while repeating reflection between the case 2 and the housing member such as the core 5 and the coil 6 housed in the case 2, and the opening of the case 2. It leaks out from the part 2a and becomes noise.

On the other hand, the lid body 7 formed of a foam having a semi-continuous and half-cell foam structure has an action of reflecting and absorbing noise leaking from the opening 2a of the case 2 to the outside.
Therefore, when the opening 2a of the case 2 is closed by the lid 7, vibration of about 10 kHz which is about to leak out from the opening 2a is reflected into the case 2 and absorbed by the lid 7. . Noise is attenuated by repeating reflection and sound absorption by the lid 7.

  Since the normal operating frequency of the in-vehicle inverter is about 10 kHz, the noise generated from the opening 2a of the case 2 is attenuated by the lid 7 to reduce the noise from the reactor as a whole. Is possible.

In this way, noise can be reduced with a simple structure in which the lid 7 made of a foam with a semi-semi-single foam structure is disposed in the opening 2a of the case 2, so that mass production can be easily performed at low cost. It is.
Moreover, since the reactor does not increase in size, noise suppression can be realized without impairing the need for downsizing required for a vehicle-mounted reactor.

Next, a second embodiment of the present invention will be described.
The reactor noise reduction device 1 shown in FIG. 4 is obtained by further attaching a cover 10 to the opening 2a of the case 2 in the noise reduction device 1 of the first embodiment.
That is, the cover 10 is further covered from above the lid body 7 arranged in the opening 2a of the case 2 to close the opening 2a.

The cover 10 is attached and fixed to the case 2 by a fastening member such as a bolt, and the lid body 7 is compressed in the vertical direction by the cover.
The compression rate in the vertical direction of the lid body 7 is set to be, for example, 50% to 70%.

In this way, by disposing the lid body 7 in the compressed state in the opening 2a of the case 2, the lid body 7 spreads in the horizontal direction so that there is no gap between the case 2 and the lid body 7, and the lid body 7 It will adhere to the surface of the sealing resin 8.
Thereby, it can prevent that a noise leaks outside from the clearance gap between the case 2 and the cover body 7, and can suppress noise efficiently.

It is a top view which shows the noise reduction apparatus of the reactor of this invention. It is a side view which similarly shows the noise reduction apparatus of a reactor. It is a front view which similarly shows the noise reduction apparatus of a reactor. It is a side view which shows 2nd embodiment of the noise reduction apparatus of a reactor.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Noise reduction apparatus 2 Case 2a Opening part 5 Core 6 Coil 7 Lid body 8 Sealing resin

Claims (4)

A reactor composed of a coil and a core is accommodated in a high heat conduction case,
After filling and curing the sealing resin in the space in the high thermal conduction case containing the reactor, the opening of the high thermal conduction case is closed with a lid made of a foam member having a semi-solid and semi-foam structure. Reactor noise reduction method characterized by this.   The reactor foam noise reduction method according to claim 1, wherein the foamed member is disposed in an opening of the high heat conduction case in a compressed state.   A high heat conduction case that accommodates a reactor composed of a coil and a core, a sealing resin that fills the space in the high heat conduction case that contains the reactor, and a semi-continuous half-cell foam structure that closes the opening of the high heat conduction case A reactor noise reduction device comprising: a lid body made of a foam member.   The reactor foam noise reduction device according to claim 3, wherein the foamed member is disposed in an opening of the high heat conduction case in a compressed state.

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