JP2007134374A - Reactor device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor device generating small noise inexpensively. <P>SOLUTION: The reactor device Y comprises a reactor X having a core 1 and a coil 2; a case 3 for storing the reactor X; and a sealing member 4 composed of inner and outer sealing members 4a, 4b interposed between the reactor X and the case 3. In the inner sealing member 4a, filler (alumina) having large specific gravity is added to a heat-resistant epoxy resin. In the external sealing member 4b, filler having large specific gravity is added to an urethan resin, thus reducing noise generated from the reactor device Y. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention mainly relates to measures for reducing noise and improving heat resistance of reactors mounted on fuel cell vehicles and hybrid vehicles.

  In recent years, automobiles that drive motors with a DC power source such as hybrid vehicles and fuel cell vehicles have been developed due to environmental problems. A boost converter disposed in a fuel cell vehicle or a hybrid vehicle includes a reactor that converts a voltage. The reactor includes a core formed by stacking a plurality of partial cores with a gap interposed therebetween, and a coil wound around the core. When a current flows through the coil, a magnetic field is generated inside the core, and a magnetic attractive force is generated between the partial cores sandwiching the gap, causing the reactor to vibrate. Noise caused by this vibration is released to the outside of the reactor device.

  Thus, how to reduce this noise is one problem. In particular, it is required to reduce high-frequency noise in the vicinity of 10 kHz (5 to 20 kHz). Therefore, conventionally, many proposals for reducing the noise generated by the reactor device have been made.

  For example, in Patent Document 1, the opening of the case that houses the reactor is closed with a lid member made of a foam member having a half-single-half structure, thereby suppressing internal vibration and noise leaking outward from the reactor device. Techniques to reduce are disclosed. In patent document 2, the technique which tries to suppress a noise by interposing a vibration isolator between cores in a reactor is disclosed.

JP 2005-72198 A JP 2004-319679 A

  However, according to experiments by the present inventors, a clear correlation has not always been found between the vibration level and the noise level. In other words, in the conventional techniques including the technique of the above publication, structural analysis for effectively preventing noise from being emitted, such as preventing vibration and preventing noise, is identified. It can be said that it was insufficient. For this reason, it has been difficult to accurately and effectively reduce the generation of high-frequency noise in the human audible range.

  In addition, since the driving current of the reactor tends to increase, Joule heat generated from the coil and heat generation from the core due to magnetic flux change have increased, and the heat resistance required for the sealing member has also increased. .

  On the other hand, generally, a resin having high heat resistance (for example, an epoxy resin) is more expensive than a resin having low heat resistance (for example, a urethane resin), and therefore, it is necessary to suppress the usage amount as much as possible. That is, it is impossible to take noise reduction measures and heat resistance improvement measures ignoring realistic costs.

  The objective of this invention is providing the reactor apparatus which has a structure which can reduce high frequency noise, considering the suppression of manufacturing cost and heat resistance.

  The reactor apparatus of this invention interposes the sealing member of the double structure which consists of an inner side sealing member and an outer side sealing member between a reactor and a case.

  As a result, the materials constituting the inner sealing member and the outer sealing member can be selected in consideration of noise, heat resistance, and cost, so that high-frequency noise is taken into consideration while considering manufacturing cost and heat resistance. Can be reduced.

  The inner sealing member contains a resin whose heat resistance is higher than that of the outer sealing member as a main component, so that heat resistance is improved by using a relatively expensive high heat resistant resin only for the inner sealing member in contact with the reactor. And cost reduction.

  The inner sealing member contains a resin whose specific gravity is larger than that of the outer sealing member as a main component, so that when the thickness required for noise reduction is ensured, While an expensive high heat resistant resin is used, an inexpensive resin can be used as the outer sealing member, so that the heat resistance can be improved and the cost can be reduced.

  By including the epoxy resin as the main component, the inner sealing member ensures the heat resistance of the inner sealing member in contact with the reactor, and reduces the amount of expensive epoxy resin used as much as possible to reduce the cost. The most commonly used resin for stopping is able to exert a high noise reduction effect due to the resin with the highest specific gravity.

  By including the urethane resin as a main component in the outer sealing member having a large usage amount, the manufacturing cost can be suppressed as low as possible.

  When at least one of the inner sealing member and the outer sealing member includes a resin and a high specific gravity filler having a specific gravity higher than that of the resin, the noise reduction function of the reactor device can be enhanced.

  In the above case, since the high specific gravity filler is made of a material having a higher thermal conductivity than the resin, the heat dissipation efficiency through the sealing member can be increased.

  When the high specific gravity filler is an inorganic material, the specific gravity can be increased while enhancing the insulating properties of the sealing member. Moreover, the heat transfer rate of the sealing member is also improved.

   The specific gravity of at least one of the inner sealing member and the outer sealing member is preferably more than 2.0.

  According to the reactor device of the present invention, the sealing member interposed between the reactor and the case has a double structure of the inner sealing member and the outer sealing member, so that the manufacturing cost can be suppressed and the heat resistance can be considered. However, it is possible to reduce the noise generated from the reactor device.

  FIGS. 1A to 1D and FIGS. 2A to 2E are perspective views illustrating an assembly process of the reactor device according to the embodiment.

  In the step shown in FIG. 1A, a pair of inner partial cores 1a formed by alternately stacking two laminated steel plates 10 and three gap spacers 11 are formed. The laminated steel sheet 10 is constituted by adhering a number of steel sheets with an impregnating varnish or an epoxy or acrylic impregnating adhesive. The gap spacer 11 is made of a nonmagnetic and insulating material such as ceramics, glass, or a glass epoxy substrate.

  Next, in the steps shown in FIGS. 1B and 1C, a resin-made inner bobbin 13 that covers the outer periphery of the laminated steel plate 11 of each inner partial core 1a is attached. At this time, the outermost gap spacer 11 of the laminated steel plate 11 is not covered with the inner bobbin 13 and protrudes.

  Next, the coil 2 is prepared in the step shown in FIG. The coil 2 includes two annular portions 21 that are spirally wound so as to surround a prismatic space, a connection portion 22 that connects the annular portions 21, and terminals 23 at both ends. The coil 2 is almost entirely covered with an insulating film, and only a pair of terminals 21 are exposed from the insulating film.

  Next, in the step shown in FIG. 2A, each inner partial core 1 a covered with the bobbin 13 is fitted into a space surrounded by each annular portion 21 of the coil 2. At this time, the gap spacers 11 at both ends of each inner partial core 1a are exposed to the space in the annular portion 21 of the coil 2.

  Next, in the step shown in FIG. 2B, the two outer partial cores 1b are attached so as to straddle the gap spacers 11 of the inner partial cores 1a. Thereby, the closed inner core 1 is constituted by the two inner partial cores 1a and the two outer partial cores 1b. Further, two resin-made outer bobbins 15 for fixing the outer partial core 1b and the coil 2 to each other are attached. Thereby, the reactor X is formed, and when the current flows through the coil 2 of the reactor X, the magnetic path of the reactor X is formed in the closed annular core 1.

  Next, in the step shown in FIG. 2C, the gap between the reactor X and the mold 5 is filled with the inner sealing member 4a by potting with heating in a state where the reactor X is housed in the mold 5. . At this time, in the present embodiment, almost the whole of the reactor X except for the terminal 23 and a portion adjacent to the terminal 23 and the bottom surface of the outer partial core 1 b is substantially sealed in the sealing member 4. In the present embodiment, the inner sealing member 4a includes an epoxy resin as a main material, various substances generally added to the epoxy resin as a filler, and alumina which is a high specific gravity filler having a higher specific gravity than the epoxy resin. Including. An epoxy resin may be applied or sprayed without using a mold.

  In this embodiment, since the viscosity of the epoxy resin is increased by adding alumina as a high specific gravity filler to the resin, potting is performed while heating the resin or the like in the step shown in FIG. However, the resin may be press-fitted by applying a pressure exceeding atmospheric pressure.

  Next, in the step shown in FIG. 2 (d), the reactor X covered with the inner sealing member 4 a is accommodated in the case 3. The case 3 is made of a material having good thermal conductivity such as Cu, Cu alloy, aluminum, or aluminum alloy, and is configured to release heat generated in the reactor X outward from the case 3.

  Next, in the step shown in FIG. 2E, the gap between the inner sealing member 4a and the case 3 is filled with the outer sealing member 4b by potting. At this time, in the present embodiment, the sealing member 4 consisting of the inner and outer sealing members 4a and 4b is substantially the whole except for the terminal 23 and the portion close to the terminal 23 of the reactor X and the bottom surface of the outer partial core 1b. It is almost sealed inside. In the present embodiment, the outer sealing member 4b is made of urethane resin as a main material, as a filler, various substances generally added to the urethane resin, and alumina which is a high specific gravity filler having a higher specific gravity than the urethane resin. Including. Thereby, the reactor apparatus Y is formed.

  FIG. 3 is a longitudinal sectional view showing a schematic structure of the reactor device Y in the present embodiment. However, in order to make it easy to see, the reactor X is shown as a side view instead of a cross-sectional structure. As shown in the figure, the bottom surface of the inner surface of the case 3 is provided with a recess for the coil 2 of the reactor X to enter, and the core 1 (outer partial core 1 b) of the reactor X is the bottom surface of the inner surface of the case 3. Is supported in contact with. And between the coil 2 and the recessed part bottom face of the case 3, the sealing member 4 which consists of inner side and outer side sealing members 4a and 4b wraps around and is interposed. Although not shown, the case 3 is installed on the heat sink, and the heat generated in the reactor X is efficiently radiated from the case 3 to the heat sink because the core 1 and the case 3 are in contact with each other.

  In the reactor device Y of the present embodiment, the gap between the reactor X and the case 3 includes an inner sealing member 4a in which alumina as a high specific gravity filler is added to an epoxy resin, and an outer sealing in which alumina is added to a urethane resin. By being filled with the member 4b, noise generated from the reactor device Y can be reduced as described later. In addition, if the entire gap is filled with the inner sealing member 4a whose main component is an epoxy resin, the manufacturing cost may increase, but the outer sealing member 4b whose main component is an inexpensive urethane resin is sealed inside. By interposing in the gap between the member 4a and the case 3, the manufacturing cost can be suppressed. The above effect will be described below while showing data.

-Experimental example-
FIG. 4 is a table showing the experimental results of examining the relationship between the type of sealing resin as a sealing member and the amount of noise change performed in the process of the present invention. The numerical value (dB) of the noise reduction effect in the figure represents the amount of noise change with respect to noise (frequency 10 kHz) when there is no sealing resin for the reactor device. In the same figure, urethane resins A and B are those of product numbers SZ-1443 and UF-1097 manufactured by Sanyu Rec Co., Ltd., respectively. Urethane resin C is a product number U-331 manufactured by Nippon Synthetic Chemical Industry. The urethane foam is manufactured by Daiichi Kogyo Seiyaku Co., Ltd., product number H-9519. The epoxy resin is Ryoden Kasei's product number R-411. The silicone RTV rubber is a product number KE-1843 manufactured by Shin-Etsu Silicone. As shown in the figure, the amount of noise change (reduction amount) tends to increase as the specific gravity of the sealing resin increases. At the same time, as a result of conducting an experiment on the vibration reduction effect, the vibration reduction effect and the noise reduction effect do not coincide with each other. There is a sample with a small vibration reduction effect despite a large noise reduction effect. That is, a clear correlation is not recognized between the specific gravity of the sealing resin and the vibration reducing effect. Patent Documents 1 and 2 describe that noise reduction can be achieved by seeking a means for reducing vibrations, but the recognition is not necessarily correct when an experiment is actually performed. I understood.

  FIG. 5 is a graph showing the correlation between the specific gravity of the sealing member and the noise reduction effect created from the data of FIG. The horizontal axis of the figure represents the specific gravity, and the vertical axis represents the noise reduction effect (dB) against noise when there is no sealing member for the reactor device. As shown in the figure, there is a significant correlation between the specific gravity of the sealing member and the noise reduction effect of the reactor device.

  Currently, the urethane resin A shown in FIGS. 4 and 5 is a widely used sealing resin. From the results of this experiment, the amount of noise is reduced by replacing the urethane resin A with an epoxy resin as a sealing member. I found out.

  On the other hand, the noise level is preferably about 5 dB or more lower than that using the urethane resin A, but the noise reduction is 3.7 dB even if the resin in the sealing member is changed from the urethane resin A to the epoxy resin. Amount. However, as the sealing member, there is a limit to increase the specific gravity of the entire sealing member only by replacing the resin as the main material with a resin having a high specific gravity. In particular, there are not many types of resins that are existing plastics and that are practical as sealing members for reactor devices.

  Therefore, the present inventors have come up with the idea of increasing the specific gravity of the sealing member and reducing noise by adding a high specific gravity filler having a higher specific gravity than the resin as the filler of the sealing member. It was. This is because if a filler having a relatively large specific gravity is selected, a considerable increase in specific gravity can be achieved. In addition, when a material having high thermal conductivity is selected as the filler, an increase in the heat dissipation effect can be expected.

  FIG. 6 shows the amount of noise change (frequency 10 kHz) when the gap between reactor X and case 3 is filled with a sealing member in which various fillers are mixed in epoxy resin (product number R-411 manufactured by Ryoden Kasei Co., Ltd.). FIG. In the figure, the noise reduction effect represents the noise reduction effect from the noise of the reactor device when no sealing member is used. A sample with a specific gravity of 2.5 and a sample with a specific gravity of 3.0 are obtained by adding alumina as a filler to an epoxy resin. In any case, the amount of filler added is adjusted so that the specific gravity is a predetermined value.

  As shown in FIG. 6, by using a sealing member obtained by adding alumina as a filler to an epoxy resin, the noise of the reactor device can be reduced by 5 dB or more than when the urethane resin A is used. . In particular, the noise of the reactor device can be reduced by using one having a specific gravity adjusted to 2.5 or more.

  On the other hand, if all the gaps between the reactor X and the case 3 are filled with a filler-added epoxy resin, the noise reduction effect and heat resistance increase, but the manufacturing cost increases. Therefore, the manufacturing cost can be suppressed by using only one of the inner sealing member 4a and the outer sealing member 4b as the main component. In particular, when the thickness necessary for the noise reduction effect is secured, the manufacturing cost can be reduced as much as possible by using an inexpensive urethane resin for the outer sealing member 4b having a larger total volume and minimizing the amount of epoxy resin used. Can be suppressed. That is, the ratio of the inner sealing member 4a and the outer sealing member 4b in the sealing member 4 can be adjusted so that a desired noise reduction amount can be secured and the manufacturing cost can be as low as possible.

  Moreover, even if the drive current of a reactor increases by making the inner side sealing member 4a which contacts a reactor directly into an epoxy resin with high heat resistance, the heat resistance of the whole sealing member 4 can be maintained favorable. .

(Other embodiments)
The structure of the embodiment of the present invention disclosed above is merely an example, and the scope of the present invention is not limited to the scope of these descriptions. The scope of the present invention is indicated by the description of the scope of claims, and further includes meanings equivalent to the description of the scope of claims and all modifications within the scope.

  In the embodiment, the resin that is the main element of the sealing member in the reactor device of the present invention has been described as a specific epoxy resin, but the resin that is the main element of the sealing member of the present invention can be other epoxy resins, various types Other resins such as urethane resin and silicone RTV rubber may be used.

  In the embodiment, the case where alumina is used as the high specific gravity filler of the sealing member in the reactor device of the present invention has been described as an example. However, the materials constituting the high specific gravity filler of the present invention are other various materials. Also good. For example, even if a metal filler is used, there is no problem as long as the insulating property of the sealing member is not impaired.

  The reactor device of the present invention can be used as a component such as a boost converter in a hybrid vehicle, a fuel cell vehicle, and a factory / household power supply system.

(A)-(d) is sectional drawing which shows the first half part of the assembly process of the reactor apparatus in embodiment. (A)-(e) is sectional drawing which shows the latter half part of the assembly process of the reactor apparatus in embodiment. It is a longitudinal cross-sectional view which shows schematic structure of the reactor apparatus in embodiment. It is a figure which shows the experimental result which investigated the relationship between the kind of sealing resin as a sealing member performed in the process of this invention, and the noise variation. It is a graph which shows the correlation of specific gravity of sealing resin and the noise reduction effect which were created from the data of FIG. It is a figure which tabulates and shows the noise reduction amount when using the sealing member formed by mixing a high specific gravity filler in an epoxy resin.

Explanation of symbols

X reactor Y reactor device 1 core 1a inner partial core 1b outer partial core 2 coil 3 case 4 sealing member 4a inner sealing member 4b outer sealing member 5 type 10 laminated steel plate 11 gap spacer 13 inner hobbin 15 outer hobbin 21 annular portion 22 connection part 23 terminal

Claims (9)

A reactor having a coil and a core;
A case for storing the reactor;
A reactor device including a double-structured sealing member that is interposed between a gap between the reactor and the case and includes an inner sealing member mainly composed of a resin and an outer sealing member. The reactor device according to claim 1,
The inner sealing member is a reactor device including, as a main component, a resin having higher heat resistance than the outer sealing member. The reactor device according to claim 1 or 2,
The inner sealing member is a reactor device including a resin whose specific gravity is larger than that of the outer sealing member as a main component. The reactor device according to claim 2 or 3,
The inner sealing member is a reactor device including an epoxy resin as a main component. In the reactor apparatus in any one of Claims 1-4,
The outer sealing member is a reactor device including a urethane resin as a main component. In the reactor apparatus in any one of Claims 1-5,
At least any one of the said inner side sealing member or an outer side sealing member is a reactor apparatus containing resin and the high specific gravity filler whose specific gravity is higher than this resin. The reactor device according to claim 6,
The high specific gravity filler is a reactor device that is a substance having a higher thermal conductivity than the resin. The reactor device according to claim 6 or 7,
The high specific gravity filler is a reactor device made of an inorganic material. In the reactor apparatus in any one of Claims 1-8,
A reactor device in which the specific gravity of at least one of the inner sealing member and the outer sealing member exceeds 2.0.

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