JP2006351673A - Reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a compact reactor having effectiveness in reduction of noises. <P>SOLUTION: The reactor 11 has a plurality of gaps 13 on each of linear portions 12a of a core 12. Gaps 13 adjacent with each other are arranged in directions different from each other so as to be tilt with respect to the direction where a magnetic flux passes, and the adjacent gaps 13 are arranged in non-parallel to each other. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a technique for reducing noise generated in a reactor.

  In recent years, so-called hybrid vehicles and electric vehicles equipped with a motor in addition to an engine as a driving force have been attracting attention due to environmental problems.

  This type of automobile is equipped with a boost converter, which boosts the battery voltage and supplies power to the inverter (motor), and steps down the regenerative current from the generator to the battery voltage to charge the battery. Have a role.

  One of the components of the boost converter is a reactor that is a coil component, and a large noise tends to be generated from the reactor.

  There are two causes of the vibration that causes this noise: the magnetostriction of the core material of the reactor itself, and the electromagnetic attraction force acting between the opposing cores in the gap portion of the reactor. Vibration due to suction force is a particularly large factor.

  For example, there is a so-called toroidal type reactor 1 as shown in FIG. 5 or FIG. 6, two straight portions 2 a are provided in the straight portion 2 a of the core 2, and a coil 4 is wound around each straight portion 2 a. It was supposed to have a structure.

  When a current flows through the coil 4, a magnetic flux is generated in the core 2, and the generated magnetic flux circulates in the annular core 2. At this time, since each gap 3 is arranged perpendicular to the direction in which the magnetic flux passes, that is, the so-called magnetic path P, vibrations generated by the electromagnetic attraction force in each gap 3 part interfere and strengthen each other. It was amplified and generated a lot of noise.

  Therefore, as shown in FIG. 7, the reactor 1 is formed in a triangular tube shape, and the amount of movement of the bending portion 2b due to electromagnetic attraction when a current flows through a coil (not shown) wound around the straight portion 2a. There has been proposed a reactor that reduces noise by reducing noise (see, for example, Patent Document 1).

JP 2005-64133 A

  However, even in the structure of such a triangular cylindrical reactor 1, each gap 3 is arranged perpendicular to the direction in which the magnetic flux passes through each straight portion 2a. There is a problem that vibrations strengthen each other and amplify.

  Furthermore, in the triangular tubular reactor 1, when a coil is wound, a dead space is easily formed on the inside, and the line area ratio cannot be increased. Therefore, the reactor is larger than a general rectangular tubular reactor. There is also the problem of doing.

  Therefore, the problem to be solved by the present invention is to provide a reactor effective for reducing noise, and further to provide a compact reactor.

  In order to solve the above problems, in the invention of claim 1, in the toroidal reactor having a plurality of gaps, at least one of the gaps adjacent to each other is arranged in an inclined shape with respect to the direction in which the magnetic flux passes, The adjacent gaps are arranged in a non-parallel manner.

  According to a second aspect of the present invention, in the reactor according to the first aspect of the invention, the gaps adjacent to each other are arranged in an inclined manner in directions different from each other with respect to the direction in which the magnetic flux passes.

  According to a third aspect of the present invention, in the reactor according to the first or second aspect of the present invention, the core of the reactor is a rectangular tube having a rectangular hole at the center.

  According to a fourth aspect of the present invention, in the reactor according to any one of the first to third aspects of the invention, the magnetic body of the core is formed of a dust magnetic material.

  According to the first aspect of the present invention, at least one of the gaps adjacent to each other is disposed in an inclined manner with respect to the direction in which the magnetic flux passes, and the adjacent gaps are disposed non-parallel to each other. Because the direction of each vibration generated by the electromagnetic attraction force is different in the adjacent gap portion, amplification by strengthening due to vibration interference as in the conventional case can be effectively prevented, and noise can be effectively reduced. There are advantages.

  According to the second aspect of the present invention, since the adjacent gaps are arranged in an inclined manner in different directions with respect to the direction in which the magnetic flux passes, the electromagnetic attraction force is applied to the adjacent gap portions. Each of the generated vibrations has a different direction, and there is an advantage that noise can be reduced more effectively by the canceling action due to vibration interference.

  According to the third aspect of the present invention, since the core of the reactor is a rectangular cylinder having a rectangular hole at the center, a dead space such as a triangular cylindrical reactor is also present when the coil is wound. It is difficult to occur, a good line area ratio can be secured, and the reactor can be made compact.

  According to the fourth aspect of the present invention, if the core magnetic body is formed of a powder magnetic material, even if the shape of the magnetic body in the core is complicated, it can be easily manufactured by press molding or the like. can do.

<First Embodiment>
1 and 2 show a reactor 11 according to the first embodiment of the present invention, and as described above, there are two gaps 13 in each of the straight portions 12a of the core 12, and a coil 14 is provided in each straight portion 12a. The core 12 has a rectangular cylindrical toroidal shape including a pair of straight portions 12a and a pair of substantially U-shaped curved portions 12b in plan view. Here, a structure having a rectangular hole 12c in the center of the core 12 is adopted. And it is used for the power supply system (especially step-up converter) for a hybrid vehicle or an electric vehicle, for example.

  Each gap 13 has a structure in which each gap 3 is arranged at an appropriate angle (θ1, θ2) with respect to a direction perpendicular to the magnetic path P in the direction in which the magnetic flux passes. At this time, each gap 13 disposed in each linear portion 12a is structured to be inclined in different directions with respect to the plane orthogonal to the magnetic path P. For example, in this embodiment, θ1 = 45 degrees, θ2 = 45 degrees. In addition, what is necessary is just to determine such an inclination angle ((theta) 1, (theta) 2) suitably as needed. Here, the adjacent gaps 13 are arranged in a non-parallel manner.

  Each magnetic body in the linear part 12a and the curved part 12b of the core 12 is composed of a metal magnetic powder or a powder magnetic body in which a metal magnetic powder covered with a predetermined insulating film is bonded with a resin, and is a dust magnetic material. Is filled in a predetermined mold, pressed and compressed by press molding or the like, and then heat-treated. In the present embodiment, each magnetic body of the linear portion 12a and the curved portion 12b of the core 12 is formed of a dust magnetic material, but a structure in which these are formed of a silicon steel plate may be used as in the related art.

  Each gap 13 is made of, for example, a plate-like member having a thickness of about 1 mm made of ceramic (alumina or the like) that is good in terms of heat resistance and linear expansion coefficient. As shown in FIG. 1 and FIG. Each of the 12 straight portions 12a is inserted and bonded with an epoxy adhesive or the like having excellent heat resistance.

  As described above, according to the present embodiment, the application of an alternating current (which may be a superposition of a direct current) to the coil 14 of the reactor 11 causes a vibration due to an electromagnetic attraction at each gap 13 portion. The adjacent gaps 13 are arranged in an inclined manner in different directions with respect to the magnetic path P. Therefore, the direction of the electromagnetic attraction force is different in the adjacent gap 13 portion, and therefore generated by the electromagnetic attraction force. Since the directions Q of the vibrations are different from each other, it is possible to effectively prevent the amplification by the strengthening due to the vibration interference as in the conventional case, and to effectively reduce the noise due to the vibrations.

  At this time, since the adjacent gaps 13 are arranged at the same angle in the different directions with respect to the magnetic path P, an efficient vibration canceling action can be exhibited, and noise can be reduced more effectively. There is an advantage. In addition, in the present embodiment, since the adjacent gaps 13 are arranged at 45 degrees inclined at the same angle in different directions with respect to the plane orthogonal to the magnetic path P, more efficient vibration can be obtained. The canceling action can be exhibited, and the noise can be reduced more effectively.

  Further, since the core 12 has a rectangular tube shape having a rectangular hole portion 12c in the center portion, when the coil 14 is wound, a dead space like the triangular tube reactor 1 as in the conventional structure hardly occurs. A good line area ratio can be secured, and the reactor 11 can be made compact.

  Further, the magnetic body of the core 12 is formed of a dust magnetic material, and can be easily manufactured by press molding or the like, and a highly flexible shape can be easily manufactured. Even if it is a magnetic body, there exists an advantage that it can manufacture easily.

Second Embodiment
FIG. 3 shows a reactor 11 according to the second embodiment of the present invention, and the same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted.

  That is, in the first embodiment, as shown in FIG. 1 and FIG. 2, each gap 13 is structured to be inclined with respect to the magnetic path P in plan view. , Each gap 13 is arranged in an inclined manner in a direction in which the magnetic flux passes, that is, in a direction different from each other with respect to the magnetic path P in a side view. Others are configured similarly to the first embodiment.

  Therefore, the present embodiment has the same effect as the first embodiment.

<Third Embodiment>
FIG. 4 shows a reactor 11 according to the third embodiment of the present invention, and the same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted.

  That is, in the present embodiment, each gap 13 is arranged in an inclined manner in a direction in which the magnetic flux passes, that is, in a direction different from each other with respect to the magnetic path P in both a plan view and a side view. The other configurations are the same as those in the first embodiment.

  Therefore, the present embodiment has the same effect as the first embodiment.

  In each embodiment, each gap 13 adjacent to each other is configured to be inclined with respect to the direction in which the magnetic flux passes. However, at least one of the adjacent gaps 13 is inclined. Or a structure in which the adjacent gaps 13 are arranged non-parallel to each other. In such a case, amplification of vibration due to strengthening as in the prior art can be effectively prevented, and noise can be reduced. There is an advantage that it can be effectively achieved.

  Moreover, in each embodiment, although it is set as the structure which has the gap 13 in two places in the linear part 12a in the core 12, one place, three places or more may be sufficient, and it can apply similarly.

  Furthermore, the structure in which the inclination angle inclined with respect to the direction in which the magnetic flux passes through each gap 13 is 45 degrees is shown in the first embodiment, but it is 45 degrees or less as shown in the second embodiment. Preferably, the inclination angle is within 45 degrees, but it may be more than that, and may be determined as needed.

  Moreover, in each embodiment, although the structure where each gap 13 was comprised flat was shown, it does not need to be flat and is not limited to the shape of embodiment at all.

It is a plane explanatory view of the core of the reactor concerning a 1st embodiment of the present invention. It is the same perspective view. It is a perspective view of the core of the reactor which concerns on 2nd Embodiment. It is a perspective view of the core of the reactor which concerns on 3rd Embodiment. It is plane explanatory drawing of the core of the reactor which concerns on a prior art example. It is the same perspective view. It is a perspective view of the core of the other reactor which concerns on a prior art example.

Explanation of symbols

11 Reactor 12 Core 13 Gap 14 Coil

Claims (4)

In a toroidal reactor having a plurality of gaps,
A reactor, wherein at least one of the gaps adjacent to each other is disposed in an inclined manner with respect to a direction in which the magnetic flux passes, and the adjacent gaps are disposed non-parallel to each other. The reactor according to claim 1,
Each of the gaps adjacent to each other is arranged in an inclined manner in directions different from each other with respect to the direction in which the magnetic flux passes. In the reactor according to claim 1 or 2,
The reactor core is a quadrangular cylinder having a rectangular hole at the center. In the reactor in any one of Claims 1 thru | or 3,
A reactor in which the magnetic body of the core is formed of a dust magnetic material.

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