JP2006351719A - Reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor capable of suppressing transmission of vibration from a case to the outside. <P>SOLUTION: This reactor includes a core 10, a coil 20 wound around the core 10, a case 30, and a sealing material 40 for sealing the core 10 and the coil 20 into the case 30. A porous material is used for the sealing material 40. The vibration of the core 10 transmitting to the outside can be reduced by utilizing the characteristic in which the vibration sound enters into pores of the porous material and is diffused, the vibration energy of sound is converted into thermal energy and the reflected sound diminishes. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a reactor. In particular, in a reactor having a core housed in a case, the present invention relates to a reactor that can suppress vibration generated from the core from being transmitted to the case.

  In recent years, hybrid vehicles have been put into practical use due to environmental problems. A hybrid vehicle is a vehicle that includes an engine and a motor as drive sources and travels using one or both of them. In such a hybrid vehicle, for example, as shown in FIG. 3, a battery 110, an inverter 120, and a traveling three-phase AC motor 130 are used.

  Among them, the inverter 120 includes a converter unit 121 that performs direct current step-up / step-down and an inverter unit 122 that performs mutual conversion between direct current and alternating current. For example, the converter unit 121 boosts a battery voltage of about 200 V to a maximum of about 500 V during driving to supply power to the inverter unit 122, and adapts the direct current output from the motor 130 via the inverter unit 122 to the battery 110 during regeneration. The battery 110 is charged with the reduced voltage. Further, the inverter unit 122 converts the direct current boosted by the converter unit 121 during traveling to a predetermined alternating current and supplies power to the motor 130, and during regeneration, converts the alternating current output from the motor 130 into direct current to the converter unit 121. Output.

  The converter unit 121 performs boosting by turning on and off an amplifying element 121A such as an FET. One of the components is a reactor 121B that is a coil component. Reactor 121B uses the characteristics of a coil that attempts to prevent the change in current that flows through the circuit, and smoothes the change when the current is going to increase or decrease due to external factors such as switching on and off. It has a function. As shown in FIG. 4, the main material constituting the reactor 121B includes a core 10 and a coil 20, which are housed in a case 30 and mounted in an inverter assembly. At that time, the core / coil combination is sealed in a non-foamed urethane resin sealing material 40 in the case 30 (as a similar technique, Patent Document 1).

JP 2005-78829 A

  However, the above-described reactor has a problem that it is not possible to sufficiently suppress the vibration transmission of the core during excitation. That is, the vibration generated from the core is transmitted through the non-foamed urethane resin sealing material to vibrate the case, which contributes to noise.

  This invention is made | formed in view of said situation, and the one of the objectives is providing the reactor which can suppress that the vibration from a core transmits to the exterior.

  The reactor of the present invention includes a core, a coil wound around the core, a case, and a sealing material that seals the core and the coil in the case. And it is characterized by using a porous material for this sealing material.

  Thus, by using the porous material as a sealing material (potting material), it is possible to reduce the transmission of the vibration of the core to the outside. In other words, the present invention utilizes the property that the vibrational sound enters and diffuses into the pores of the porous material, whereby the vibrational energy of the sound is converted into thermal energy and the reflected sound is reduced. Furthermore, since it is a porous material, the weight can be reduced as compared with a conventional potting material.

  The porous material here may be an open cell in which each bubble in the material is continuous with an adjacent bubble, or may be a closed cell in which each bubble is not continuous but independent. Furthermore, the thing of the semi-continuous bubble in which a closed cell and an open cell are mixed may be used. Specifically, foamed plastic, glass wool, rock wool and the like can be suitably used. Examples of the foamed plastic include foamed polystyrene, foamed polyethylene, foamed polypropylene, foamed polyurethane, and foamed rubber. Examples of the foamed rubber include synthetic rubbers such as foamed chloroprene rubber, foamed ethylene propylene rubber, and foamed silicon rubber.

  The sealing material is preferably excellent in sound-absorbing property, but it is also a preferable characteristic that it is excellent in thermal conductivity and impact resistance.

  Usually, the reactor is accommodated in the case with a coil wound around a core. The core is generally composed of a magnetic material such as an iron-based material. In addition, a core having a configuration in which a gap made of an insulating material is sandwiched between magnetic materials may be used. The coil typically uses a conductive wire having an insulating coating. And by storing the combination of the core and the coil in the case and further filling the case with a porous material, the combination can be sealed in the case, and the vibration of the core is transmitted to the case. Can be suppressed.

  According to the present invention, the vibration sound enters the pores of the porous material and diffuses, so that the vibration energy of the sound is converted into thermal energy, and the reflected sound is reduced. Transmission to the outside can be suppressed.

  Hereinafter, embodiments of the present invention will be described with reference to FIGS. 1 and 2. Here, the reactor used for the converter part for hybrid vehicles shown in FIG. 3 is demonstrated as an example.

Example 1
The reactor is held by the core 10, the coil 20 formed by winding a conducting wire around the core 10, the inner frame 25 (FIG. 1) that holds the combination of the core 10 and the coil 20, and the inner frame 25. The case 30 is configured to house the core 10 and the coil 20, and the sealing material 40 (FIG. 2) filled in the case 30.

  First, the core 10 is an annular member made of a magnetic material. A tape-shaped conducting wire 21 is wound around the core 10 edgewise. Here, the coil 20 is formed by winding a conducting wire 21 in one direction around one winding portion of the core 10 and winding a conducting wire around the other winding portion in the same winding direction. The conducting wire 21 of one winding part and the conducting wire 21 of the other winding part have a series length. The conductor wire 21 was a copper wire coated with enamel.

  Next, the combined body of the core 10 and the coil 20 is held on the inner frame 25. The inner frame 25 has side walls that substantially cover both side surfaces of the coil 20, and has a frame portion on the front and back surfaces, and a part of the core 10 is exposed from the frame portion.

  Subsequently, the core 10 and the coil 20 are stored in the case 30 while being held by the inner frame 25 (FIG. 1). The case 30 has a rectangular parallelepiped shape with a bottom and an open top. Here, an aluminum case 30 was used.

  Then, as shown in FIG. 2, this case 30 is filled with a urethane foam sealing material 40, and the combination of the core 10, the coil 20, and the inner frame 25 is sealed in the case 30. At this time, this combination was buried in the sealing material 40.

(Examples 2 to 4, comparative example)
Moreover, the same reactor which substituted the sealing material 40 in the said Example 1 with foaming ethylene propylene rubber (foaming EPDM), glass wool, or rock wool was produced as Examples 2-4. Furthermore, as a comparative example, as shown in FIG. 4, a reactor using non-foamed polyurethane as the sealing material 40 was also produced.
(Test example)

  Using the prototypes (Examples 1 to 4 and the comparative example), it was tested how much the vibration of the core is transmitted to the case. The test method was performed by vibrating the core in a simulated manner, detecting the vibration with an accelerometer attached to the case, and analyzing with a FET analyzer. As a result, it was found that all examples were able to suppress the transmission of vibration compared to the comparative example.

  INDUSTRIAL APPLICABILITY The present invention can be used as a reactor that is expected to suppress core vibration, particularly as a reactor in a converter unit of a hybrid vehicle or an electric vehicle.

It is an assembly perspective view of this invention reactor. It is a schematic block diagram of this invention reactor. It is a schematic circuit diagram which shows the power supply system of a hybrid vehicle. It is a schematic block diagram of the conventional reactor.

Explanation of symbols

10 core
20 coil 21 conductor
25 Inner frame
30 cases
40 Encapsulant
110 Battery 120 Inverter 130 Three-phase AC motor
121 Converter section
121A Amplifier 121B Reactor
122 Inverter section

Claims (4)

A reactor comprising a core, a coil wound around the core, a case, and a sealing material for sealing the core and the coil in the case,
A reactor using a porous material as the sealing material.   The reactor according to claim 1, wherein the sealing material is a foamed plastic.   3. The reactor according to claim 2, wherein the foamed plastic is at least one selected from the group consisting of foamed polystyrene, foamed polyethylene, foamed polypropylene, foamed polyurethane, and foamed rubber.   The reactor according to claim 1, wherein the sealing material is glass wool or rock wool.

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