JP2007180145A - Magnetic component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a compact magnetic component while reducing the vibration of a reactor. <P>SOLUTION: Sidewalls 21b, 21d of a metal case 21 arranged close to or adjacent to a magnetic connection section 6 of the core of the reactor 1 have large bending stiffness to the post section of the core of the reactor 1 and a sidewall close to a coil 11 wound around the post section, and are adhered to the outer end face of the magnetic connection section 6 directly or via an interposed member, thus appropriately reducing the vibration components in the direction of the magnetic path of the post section in the core vibrations of the reactor 1. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a magnetic component formed by winding a coil around a soft magnetic core. Here, the magnetic component includes both a reactor having one type of coil and a transformer having a plurality of types of coils. However, a reactor normally has a gap for preventing magnetic saturation in a magnetic path, but a transformer is required to minimize the gap.

  For example, in a power electronic circuit device such as a vehicle DCDC converter described in Patent Document 1 below, magnetic components such as a reactor and a transformer are widely used for applications such as current smoothing and input / output electrical insulation. A choke coil having a soft magnetic core is the same as a reactor. The DC-DC converter essentially requires high-speed switching, and superimposes a high-frequency switching noise voltage on the input voltage or output voltage. However, fluctuations in the voltage of the battery, which is a vehicle power supply, adversely affect its life. Therefore, in a DC / DC converter for a vehicle, a smoothing reactor that smoothes the input power or output power is an essential component. A DC / DC converter for a vehicle equipped with this type of reactor (including a choke coil with a core) is described in, for example, the following Patent Document 1 proposed by the present applicant.

  As a reactor used in a power range (several tens of watts to several tens of kW) applied to this type of vehicle power electronic circuit device, a dry reactor that is not immersed in oil is common. The most common type of this dry reactor is the columnar core having two pillars parallel to each other and two beams that magnetically connect the ends of these pillars. Coiled. As another modified form, there is also known a Japanese character core in which one column portion is further added in parallel with the two column portions of the square core and the central column portion is a common magnetic path. Since these square-shaped cores and date-shaped cores have a square core shape, they are also referred to as square cores hereinafter. In addition, a sealed core having a peripheral wall-shaped column portion around a central column portion around which a coil is wound is known. Since this core has a short cylindrical shape or a thick disk shape, it is also referred to as a disk-shaped core hereinafter. A magnetic part having a disk-shaped core has the advantage that the electromagnetic noise is reduced because the coil is surrounded by the peripheral wall-shaped column part, and the coil length can be shortened, compared with the magnetic part having a square core. Usually, there is a disadvantage that the idle space is large in the case of the power electronic circuit device having a rectangular shape.

  In magnetic parts, it is known that a stretching force acts on the core in the direction of magnetic flux. In other words, in a rectangular core having a plurality of column portions that are wound around a coil and extending in parallel and a beam portion that connects both ends of the column portion, the magnetic flux changes in the respective magnetic path directions in the column portion and the beam portion. Accordingly, the expansion / contraction force, in other words, the vibration force acts to vibrate the column portion and the beam portion. This vibration is widely known as magnetic vibration.

  It is also widely practiced to house magnetic parts in a metal square case. This rectangular case has a mechanical protection effect and an electromagnetic noise reduction effect. Hereinafter, the magnetic component built in the rectangular case is also referred to as a case built-in magnetic component. In a case built-in type magnetic component, it is usual to fasten a portion where a core coil is not wound to, for example, a bottom plate of the case. Usually, the bottom plate of the case to which the core is fastened also serves as a heat radiating member that radiates the heat of the core.

  The core constituting the magnetic closed circuit interlinking with the coil is configured by combining a plurality of partial cores for coil insertion or the like. That is, the core of the magnetic component has a split core structure. For this reason, a gap is generated between the end faces of the two partial cores facing each other. In order to prevent magnetic saturation, the width of the gap is positively increased in the reactor. Often, three or more partial cores are combined to form a magnetic component core. For this reason, fixing each partial core which comprises a core to a case (for example, the baseplate) by fastening, welding, etc. is performed, respectively.

  When each partial core is fastened to the bottom plate of the case, the gap (interval) changes due to the temperature rise of the core having a coefficient of thermal expansion different from that of the case, and the inductance value of the magnetic component changes. Problems such as increased magnetic vibration transmission and increased release of magnetic noise to the outside, and strong mechanical stress on the partial core due to the magnetic vibration and thermal expansion occur.

In order to improve this problem, the following Patent Document 2 discloses that a pair of beam portions on both sides of a core pillar portion (coil winding portion) are parallel to the main surface of the bottom plate with respect to the bottom plate of the case. We propose a structure that supports displacement in various directions, especially in the gap width direction. As this support structure, for example, a method is proposed in which both ends are extended in the magnetic path direction of the beam portion on the upper surface of the beam portion of the core by a spring steel pressing plate fixed to the bottom plate of the case.
JP 2000-014149 A JP 2004-241475 A

  However, the above-described core support structure of Patent Document 1 has the function of mechanically supporting the core on the bottom plate of the case while allowing the core to move relative to the bottom plate of the case in the surface direction of the bottom plate. It is realized by the force to press against. That is, if the force applied to the core is smaller than the frictional force of the core against the bottom plate of the case, the core remains stationary with respect to the bottom plate of the case, and the force applied to the core is the frictional force of the core against the bottom plate of the case. If it is larger, the core is displaced relative to the bottom plate of the case. Therefore, it is difficult to adjust the force for pressing the core against the bottom plate of the case. In particular, it is necessary to adjust the force with which the core is pressed against the bottom plate of the case with two beam portions at both ends of the core column portion, which complicates the work.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a magnetic component that can relieve stress applied to the core by a simple mechanism.

  The magnetic component of the first invention made to solve the above-described problem has a soft magnetic circuit having a closed magnetic circuit having at least two pillar portions parallel to each other and a magnetic coupling portion for magnetically connecting the end portions. A magnetic core; a coil wound around the pillar; and a rectangular box-like case in which the core is accommodated and fixed; and the case is disposed on both sides of the pillar in the magnetic path direction. A main side wall extending substantially parallel to the magnetic coupling portion of the core; and a sub-side wall extending substantially parallel to the column portion of the core while being close to the column portion of the metal case, However, in the magnetic component that expands and contracts in the magnetic path direction by alternating current energization to the coil, the main side wall has a bending rigidity in the thickness direction larger than the sub side wall and contacts the magnetic coupling part of the core. It is characterized by having. The core is preferably formed in a substantially square shape to form a so-called square core. The square core referred to in the present specification refers to a core having a substantially flat outer surface on which a column portion around which a coil is wound. Of course, the boundary between the two substantially flat outer surfaces of the square core may be chamfered and curved.

  That is, the magnetic component according to the present invention has the bending rigidity in the magnetic path direction (that is, the thickness direction) of the column portions of the two main sidewalls on both sides in the magnetic path direction of the column portion of the side wall of the case, and the thickness of the sub-side wall. By making it larger than the bending rigidity in the vertical direction, the case is characterized in that the case reduces the magnetic vibration, particularly the extension, in the direction of the core magnetic path of the core while suppressing an increase in the weight and physique of the case.

  The main side wall of the case may simply contact the magnetic coupling part of the core, or may be mechanically coupled by some means. In the former case, expansion of the core in the column magnetic path direction can be suppressed, and in the latter case, expansion and contraction of the core in the column magnetic path direction can be suppressed. In other words, the magnetic vibration of the case can be reduced without performing precise adjustment of the frictional force between the core and the case as in Patent Document 1.

  In a preferred aspect, the main side wall is thicker than the sub-side wall. If it does in this way, the above-mentioned rigidity of the main side wall can be strengthened easily.

  In a preferred aspect, the main side wall has reinforcing ribs extending toward the sub-side wall on both sides of the main side wall. If it does in this way, the above-mentioned rigidity of the main side wall can be strengthened, suppressing the weight increase of the main side wall.

  In a preferred aspect, the main side wall has a protrusion that protrudes toward the magnetic coupling portion of the core and contacts the magnetic coupling portion. In this way, this protrusion reinforces the rigidity of the main side wall and enables mechanical engagement, for example, contact between the magnetic coupling portion of the core and a suitable portion of the main side wall of the case.

  The magnetic component of the second invention made to solve the above-mentioned problem is a soft component that forms a closed magnetic circuit having at least two column parts parallel to each other and a magnetic coupling part that magnetically connects the end parts. A magnetic core; a coil wound around the pillar; and a rectangular box-like case in which the core is accommodated and fixed; and the case is disposed on both sides of the pillar in the magnetic path direction. A main side wall extending substantially parallel to the magnetic coupling portion of the core; and a sub-side wall extending substantially parallel to the column portion of the core while being close to the column portion of the metal case, However, in the magnetic component that expands and contracts in the magnetic path direction due to the alternating current energization of the coil, the core is supported by the main side wall and abuts or is coupled to the magnetic coupling portion to move the core in the magnetic path direction of the column portion. It has an interposed member for restricting expansion and contraction.

  That is, according to the present invention, vibration in the core magnetic path direction of the core is transmitted to the main side wall of the case through the interposed member, but due to the bending rigidity of the interposed member and the main side wall in the column magnetic path direction, Vibration in the direction of the column magnetic path is suppressed. The interposed member and the case are separate members, but it is also possible to mechanically couple them. Further, although the interposed member and the magnetic coupling portion of the core are separate members, it is also possible to mechanically couple them. Such mechanical coupling is effective in reducing chatter of the interposed member alone.

  In a preferred aspect, the interposed member is located between the main side wall and the magnetic coupling portion and extends in a magnetic path direction of the magnetic coupling portion. If it does in this way, the bending rigidity of an interposed member can be strengthened, suppressing the weight increase of an interposed member.

  DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments of a reactor adopting the present invention will be described with reference to the drawings. This reactor is used for current smoothing of a DCDC inverter for vehicles. However, the present invention should not be construed as being limited to the following embodiments, and it goes without saying that the technical idea of the present invention may be realized using other known techniques.

(First embodiment)
The whole structure of this reactor is shown in FIG.1 and FIG.2. The reactor 1 has a soft magnetic square core 2 and a coil 3 wound around the square core 2.

(core)
The U-shaped core 2 is formed by abutting two U-shaped cores 4 having the same shape. The U-shaped core 4 will be described with reference to FIGS. The U-shaped core 4 has two rectangular column portions 5 and one magnetic coupling portion 6 each formed by molding soft magnetic powder, and is formed in a U shape as a whole.

  The square column part 5 has two end faces (hereinafter also referred to as magnetic path end faces) through which magnetic flux enters and exits, and these two magnetic path end faces are arranged in parallel so as to face away from each other. The magnetic coupling portion 6 is a member that magnetically couples two rectangular column portions 5 that are arranged in parallel to each other, and has a small number of column portions that are continuous with the rectangular column portion 5. Bolt fastening holes 7 are formed in each corner of the magnetic coupling part 6 in the direction perpendicular to the magnetic path. The magnetic coupling part 6 has two magnetic path end faces on the same plane, and a magnetic path gap is formed between one magnetic path end face of the magnetic coupling part 6 and one magnetic path end face of one rectangular column part 5. A non-magnetic and electrically insulating spacer 8 is formed for forming the. In the U-shaped core 4 shown in FIGS. 3 and 4, the end surfaces of the magnetic paths on the side opposite to the spacer 8 of the two rectangular column parts 5 are exposed. The exposed magnetic path end faces of the two rectangular column parts 5 are also referred to as exposed magnetic path end faces 9. The B-shaped core 2 is configured by individually butting two exposed magnetic path end faces 9 of the two U-shaped cores 4 respectively. Note that a spacer similar to the spacer 8 is interposed between the two exposed magnetic path end faces 9 that are abutted with each other, as will be described later. The two rectangular column parts 5 which are abutted with each other are substantially accommodated in the coil 3 to form the column part referred to in the present invention. Therefore, the square-shaped core 2 is composed of two pillar portions and two magnetic coupling portions 6. Hereinafter, the two pillar portions may be referred to as a first pillar portion and a second pillar portion.

(coil)
The coil 3 is shown in FIG. The coil 3 is formed by connecting a first coil portion 10 wound around the first pillar portion of the lower core 2 and a second coil portion 11 wound around the second pillar portion of the lower core 2 in series. Become. Since the total four rectangular column parts 5 constituting the first column part and the second column part each have a prismatic shape, the first coil part 10 and the second coil part 11 each have a rectangular cylindrical coil shape. The first coil portion 10 and the second coil portion 11 are configured by bending a thick plate-like rectangular wire whose surface is coated with an insulating film in the width direction. The coil 3 is formed by winding a single flat wire, and the thickness direction of the flat wire is parallel to the magnetic path direction of the rectangular column portion 5.

  The coil 3 will be described in more detail with reference to FIG.

  Reference numerals 12 to 15 denote end portions (also referred to as terminal portions) of the first coil portion 10 and the second coil portion 11, and the insulating film at the tip portions is peeled off by a predetermined dimension. The first end portion 12 of the first coil portion 10 protrudes forward from the lower left side of the first coil portion 10, and the end portion 13 of the first coil portion 10 protrudes forward from the upper right side of the first coil portion 10. The end portion 14 of the second coil portion 11 protrudes forward from the upper left side of the second coil portion 11, and the start end portion 15 of the second coil portion 11 protrudes forward from the upper left side of the second coil portion 11. Further, the terminal end portion 13 of the first coil portion 10 and the start end portion 15 of the second coil portion 11 are overlapped and welded in the vertical direction in FIG. 5, that is, in the magnetic path direction (column portion magnetic path direction) of the rectangular column portion 5. ing.

(Half core)
The U-shaped core 4 and the spacer 8 described above are integrated by resin insert molding to constitute a U-shaped half core 16 shown in FIG. That is, the U-shaped half core 16 includes the U-shaped core 4 and the spacer 8 and the resin coating portion 17 that covers them. As shown in FIG. 6, the resin coating portion 17 has irregularities for engaging and fitting the two U-shaped half cores 16. In this embodiment, the exposed magnetic path end surfaces 9 of the two rectangular column parts 5 are exposed from the resin coating part 17, but may be covered by the resin coating part 17 to a substantially constant thickness. In this case, the portion of the resin coating portion 17 that covers the exposed magnetic path end face 9 constitutes a spacer.

  The resin coating portion 17 is located at the center in the left-right direction of the two rectangular column portions 5 (actually covered by the resin coating portion 17) arranged in parallel with each other, and extends in the front-rear direction. The support 18 is integrally provided. The sensor holding spacer 18 may be manufactured separately from the resin coating portion 17. The sensor holding spacer 18 is a resin plate and is nonmagnetic and electrically insulating. Eventually, the square core 2 of the reactor 1 has a total of six magnetic gaps. The sensor holding spacer 18 is chamfered at the front and upper corners to constitute a linear taper surface 19 for defining a groove for inserting a temperature sensor described later.

(Assembly of reactor 1)
The assembly of the two U-shaped half cores 16 and the coil 3 will be described with reference to FIG. A spacer 20 is disposed between the exposed magnetic path end faces 9 of the two U-shaped half cores 16. The spacer 20 is, for example, a plate material such as resin, glass, or ceramic, and is fixed to the core end surface with an adhesive. Reactor 1 formed in this way is housed in a metal case 21 made of an aluminum alloy having a front end opening as shown in FIG. 8. Mold resin 22 is sealed in metal case 21 to seal reactor 1. ing.

  As shown in FIG. 8, the metal case 21 has a stepped protrusion 23 a protruding rearward at the center in the vertical direction of the bottom surface 23 on the rear end side. The metal case 21 has case holes 24 (see FIG. 9) respectively communicating with the two bolt fastening holes 7 provided in either of the two U-shaped cores 4. In FIG. 24 is not visible.

(Vehicle DCDC converter)
Next, the operation of assembling the reactor 1 to the vehicle DCDC converter will be described below with reference to FIG. FIG. 9 is a diagram illustrating a main part of the DC-DC converter for a vehicle.

  25 is a liquid-cooled inverter device for a DC-DC converter for a vehicle, and this inverter device 25 has a semiconductor card module 26 in which main electrodes are exposed on a total of 12 surfaces each incorporating a semiconductor element. The card module 26 is alternately stacked with a total of 13 liquid cooling fins 27. In addition, an electrical insulating film or sheet is interposed between the semiconductor card module 26 and the liquid cooling fin 27 for electrical insulation during the lamination. Note that a total of 12 semiconductor card modules 26 constitute switching elements or flywheel diodes for each of the three-phase arms. The liquid cooling fins 27 are formed by overlapping two identical aluminum plates and brazing their outer peripheral edges, and a liquid flow path is formed in the vertical direction inside. In addition, among the liquid cooling fins 27, black thick lines extending vertically in FIG. 9 indicate outer peripheral edges of the brazed liquid cooling fins 27. The upper ends of the liquid cooling fins 27 are brazed so that the liquid flow paths are formed in the left-right direction, thereby forming a so-called inflow header. Similarly, the lower end portions of the liquid cooling fins 27 are brazed so that the liquid flow paths are formed in the left-right direction, thereby forming a so-called outflow header. In FIG. 9, a cooling liquid inflow pipe 29 and a cooling liquid outflow pipe 30 are brazed to the rightmost liquid cooling fin 27. Of course, the coolant inflow pipe 29 communicates with the right end of the inflow header, and the coolant outflow pipe 30 communicates with the right end of the outflow header.

  Reference numeral 31 denotes an aluminum alloy converter housing (case referred to in the present invention) that houses a DCDC converter for a vehicle, and is die-cast in a square box shape with one end opening. The above-described liquid cooling type inverter device 25 is fixed to the converter casing 31 together with the liquid cooling device having the SPS structure described above.

  Adjacent to the right end of the liquid-cooled inverter device 25, the reactor 1 is fixed by a bolt (not shown) that passes through the bolt fastening hole 7 and the case hole 24 and is fastened to the converter housing 31. . Only the bolt fastening hole 7 of the magnetic connecting portion 6 on the upper end side of the reactor 1 is fastened, but the bolt fastening hole 7 of the magnetic connecting portion 6 on the lower end side of the reactor 1 is free. That is, the reactor 1 and the metal case 21 to be accommodated do not have the case hole 24 communicating with the bolt fastening hole 7 of the magnetic coupling portion 6 on the lower end side of the reactor 1, and as a result, the reactor 1 is connected to the converter housing 31. One end is supported in the column magnetic path direction (vertical direction in FIG. 9), and the magnetic coupling portion 6 on the lower end side of the reactor 1 is a free end with respect to the converter housing 31 in the metal case 21.

  A side wall 21 a on the left end side of the metal case 21 that houses the reactor 1 is disposed in close contact with the right main surface of the rightmost liquid cooling fin 27 that forms the right end surface of the liquid cooling inverter device 25. In addition, in order to improve the adhesiveness between the left end side wall 21a of the metal case 21 and the rightmost liquid cooling fin 27, heat conductive grease may be applied, or both may be joined by various methods. .

  Of the first coil portion 10 and the second coil portion 11 in the metal case 21, the outer peripheral surface of the first coil portion 10 is the rightmost side via the mold resin in the metal case 21 and the side wall 21 a of the metal case 21. The liquid cooling fins 27 are cooled. That is, among the liquid cooling fins 27 of the liquid cooling type inverter device 25, the outer main surface of the outermost liquid cooling fin 27 is not used for cooling the semiconductor module. The outer main surface of the cold fin 27 is used for heat transfer cooling of the reactor 1.

  In this embodiment, the outermost liquid cooling fin 27 faces the outer peripheral surface of the first coil portion 10 through the side wall of the metal case 21 and the mold resin. Thereby, the coil 3 that needs to be cooled in preference to the core is cooled well. The second coil part 11 is cooled well through the excellent thermal conductivity of the rectangular wire constituting the first coil part 10. Note that the arrangement of the reactor 1 may be changed so that both the outer peripheral surface of the first coil unit 10 and the outer peripheral surface of the second coil unit 11 are opposed to the outermost liquid cooling fin 27.

  Further, since the cooling liquid inflow pipe 29 and the cooling liquid outflow pipe 30 are interposed, the metal case 21 is accommodated in the metal case 21 by bringing the cooling liquid inflow pipe 29 and the cooling liquid outflow pipe 30 into contact with each other. The reactor 1 thus made can be cooled well from three sides.

(Modification)
In the above embodiment, the metal case 21 and the converter housing 31 are configured separately and fastened. However, as shown in FIG. 10, the metal case 21 that accommodates the reactor 1 and the converter housing 31 are integrally formed with a die. It may be cast to form an integral case. In this case, the side wall 21 a, which is one of the four rectangular side walls corresponding to the metal case 21 of the integral case, comes into contact with the outermost liquid cooling fin 27.

  The four side walls of the metal case 21 include a side wall 21 a that faces the outer peripheral surface of the first coil unit 10, a side wall that faces the outer peripheral surface of the second coil unit 11, and two side walls that face the magnetic coupling unit 6. . Here, when the side wall 21a of the metal case 21 facing the first coil portion 10 (or the outer peripheral surface of the second coil portion 11) is in close contact with the outermost liquid cooling fin 27 (when the coil is brought close to the cooler) a When the side wall of the metal case 21 facing the magnetic coupling portion 6 of the square core 2 is in close contact with the outermost liquid cooling fin 27 (when the core is brought close to the cooler) b, The center temperature of the reactor 1 was measured. The measurement results are shown in FIG. In FIG. 11, with the passage of time in a state where a constant current was passed through the coil, in the case of a, the temperature slightly exceeded 100 ° C., but in the case of b, the value was close to 120 ° C. .

  Next, the arrangement of the temperature sensor 32 used for the temperature detection will be described with reference to FIGS. The temperature sensor 32 has a built-in thermistor and is disposed at a central position X (see FIG. 2) in the column magnetic path direction of the coil 3 in an intermediate gap between the first coil unit 10 and the second coil unit 11. Yes. Moreover, it arrange | positions in the front-back direction center part (refer FIG. 8) which is the axial direction of the 1st coil part 10 and the 2nd coil part 11. As shown in FIG. That is, the temperature sensor 32 is arranged at the three-dimensional center position X of the reactor 1. This position is a portion where the temperature is highest in the reactor 1 due to heat generated by the first coil unit 10 and the second coil unit 11 on both sides, and the temperature sensor 32 detects the maximum temperature of the reactor 1. The measurement result of each part temperature of the reactor 1 is shown in FIG. It can be seen that the temperature at the central position X of the reactor 1 is considerably higher than the coil temperature (peripheral part) and the core temperature (peripheral part).

  The arrangement of the temperature sensor 32 will be described in more detail with reference to FIG.

  The sensor holding spacer 18 integrally formed with the resin coating portions 17 of the two U-shaped cores 4 faces the vertical direction and forms a groove portion 18A in which the temperature sensor 32 is accommodated. The groove 18A has an opening that is partitioned by the linear tapered surfaces 19 of the two sensor holding spacers 18 and gradually increases toward the front. The straight bar-shaped temperature sensor 32 is inserted from the opening of the groove 18A to the center position (see FIG. 2) X. After the temperature sensor 32 is inserted, a liquid or jelly-like mold resin is injected into the metal case 21 and solidified, whereby the reactor 1 and the temperature sensor 32 are fixed at predetermined positions. The sensor holding spacer 18 holds the temperature sensor 32 when the mold resin is injected to prevent displacement. In the case where the two sensor holding spacers 18 are formed separately from the resin coating portion 17, the two sensor holding spacers 18 can be replaced by one grooved resin plate.

(Vibration reduction structure of metal case 21)
Next, the vibration reduction structure of the metal case 21 shown in FIG. 10 will be described. As described above, the metal case 21 is formed integrally with the converter casing 31, and the four side walls 21 a to 21 d of the substantially rectangular frame-shaped metal case 21 are the side walls 31 a to 31 d of the outer converter casing 31. Are formed in parallel. The bottom plate 21 e of the metal case 21 also serves as the bottom plate 31 e of the converter housing 31. Further, the beam portions 411 to 414 protrude from the outer surface of the metal case 21 at a substantially right angle. The beam portion 411 is integrated with the side wall and the bottom plate 31 e of the converter housing 31, and the beam portions 412 to 414 are integrated with the bottom plate 31 e of the converter housing 31. In addition, there is a beam portion that connects the outer surface of the side wall 21d of the metal case 21 and the bottom plate 31e of the converter housing 31, but this is not shown in FIG. However, no beam portion is formed on the side wall 21 a of the metal case 21. Thereby, the heat radiation of the reactor 1 inside the metal case 21 can be improved through the metal case 21 by bringing the side wall 21a into close contact with the liquid cooling fin 27 of the liquid cooling type inverter device.

  In this embodiment, since the metal case 21 is formed integrally with the converter housing 31, even if the side walls 21a to 21d of the metal case 21 are thinned, the bending rigidity in the thickness direction of the metal case 21 is improved. Yes. In addition, it can be seen that the beam portions 41 to 44 remarkably improve the bending rigidity of the side walls 21 a to 21 d of the metal case 21.

  In particular, the beam portion 412 can satisfactorily reduce the vibration of the side wall 21b in the thickness direction due to the vibration in the column magnetic path direction of the rectangular column portion 5 of the reactor 1. Further, since the beam portions 411, 413, and 414 project from the side wall corners of the metal case 21 at a right angle to the side wall corners, the vibration in the column magnetic path direction of the reactor 1 and the magnetic coupling portion magnetism. It is possible to satisfactorily reduce the vibration of the side walls 21a to 21d of the metal case 21 due to both the vibrations in the road direction. Moreover, the vibration reduction of these side walls 21a-21d also implement | achieves the vibration reduction of reactor 1 itself. Further, the beam portions 411 to 414 improve the heat radiation from the metal case 21 to the converter housing 31.

  Further, in this embodiment, the side walls 21b and 21d on both sides in the column magnetic path direction of the reactor 1 are formed thicker than the side walls 21a and 21c on both sides in the magnetic coupling section magnetic path direction of the reactor 1. Thereby, the big vibration of the side walls 21b and 21d due to the vibration of the reactor 1 in the column magnetic path direction larger than the vibration in the magnetic coupling part magnetic path direction can be reduced satisfactorily. The side walls 21b and 21d constitute the main side wall as referred to in the present invention, and the side walls 21a and 21c constitute the sub-side wall referred to in the present invention.

(Second Embodiment)
Another embodiment for reducing the vibration in the direction of the magnetic pole of the reactor 1 and the metal case 21 will be described with reference to FIGS. 13 and 14. FIG. 13 is a schematic front view of the reactor device, and FIG. 14 is a schematic cross-sectional view of the reactor device.

  As in the first embodiment, the rectangular box-shaped metal case 21 has side walls 21 a to 21 d and a bottom plate 21 e, and the bottom plate 21 e has step surfaces 21 f and 21 g for mounting the magnetic coupling portion 6. The magnetic coupling portion 6 may be fastened to the step surfaces 21f and 21g, or may be fixed only by the mold resin 22 without being fastened.

  Also in this embodiment, the side walls 21b and 21d on both sides in the column magnetic path direction are formed thicker than the side walls 21a and 21c on both sides in the magnetic coupling part magnetic path direction, and the bending rigidity thereof is enhanced. For this reason, the big vibration of the column part magnetic path direction of the reactor 1 can be suppressed favorably. In FIG. 13 and FIG. 14, the mold resin 22 is interposed between the inner surfaces of the side walls 21b and 21d and the magnetic coupling portion 6. However, a spacer with a predetermined thickness is attached directly or later. Molding may be performed after press-fitting.

(Third embodiment)
Another embodiment for reducing the vibration in the column magnetic path direction of the reactor 1 and the metal case 21 will be described with reference to FIGS. 15 and 16. FIG. 15 is a schematic partial cross-sectional view of the reactor device, and FIG. 16 is a schematic partial front view of the reactor device.

  In this embodiment, the beam plate portion protruding from the inner side surfaces of the side walls 21b and 21d on both sides in the magnetic path direction of the metal case 21 toward the magnetic coupling portion 6 and in contact with the outer end surface of the magnetic coupling portion 6 (referred to in the present invention). Reinforcing ribs) 211 are provided. The beam plate portion 211 may be formed integrally with the side walls 21b and 21d, which are main side walls, or may be formed separately and then integrated with the side walls 21b and 21d by fastening or the like.

  The beam plate portion 211 is disposed at the center in the H direction of the magnetic coupling portion 6. Thereby, the expansion and contraction force of the magnetic coupling portion 6 in the column magnetic path direction does not generate undesirable stress in the magnetic coupling portion 6, and problems such as cracking of the magnetic coupling portion 6 can be reduced. Both ends of the beam plate portion 211 are integrated with the side walls 21a and 21c, but this is not essential. Since the side walls 21b and 21d are substantially integrated with the side walls 21b and 21d, the bending rigidity in the thickness direction of the side walls 21b and 21d is remarkably improved. Further, the beam plate portion 211 can constitute a heat radiation path from the magnetic coupling portion 6 to the metal case 21.

(Fourth embodiment)
Another embodiment for reducing vibration in the direction of the magnetic pole of the reactor 1 and the metal case 21 will be described with reference to FIGS. 17 and 18. FIG. 17 is a schematic partial cross-sectional view of the reactor device, and FIG. 18 is a schematic partial front view of the reactor device.

  In this embodiment, the end plate of the beam plate portion 211 of the third embodiment is provided with a gutter plate portion 212 extending in parallel with the side walls 21b and 21d while being in contact with the outer end surface of the magnetic coupling portion 6, and the side wall 21b, beam The plate portion 211 and the gutter plate portion 212 are formed into a rail shape as a whole. In this way, it is possible to smoothly transfer vibration force between the magnetic coupling portion 6 and the beam plate portion 211, to reduce stress in the magnetic coupling portion 6, and from the magnetic coupling portion 6 to the beam plate portion. Heat transfer to 211 can be improved. Of course, also in this case, the beam plate portion 211 and the gutter plate portion 212 may be formed separately, or may be mechanically coupled or joined.

(Fifth embodiment)
Another embodiment for reducing vibration in the direction of the magnetic pole of the reactor 1 and the metal case 21 will be described with reference to FIGS. 19 and 20. FIG. 19 is a schematic partial cross-sectional view of the reactor device, and FIG. 20 is a schematic partial front view of the reactor device.

  In this embodiment, the beam plate portion 211 of the fourth embodiment is separated from the side walls 21 b and 21 d, and the end plate portion 213 is provided at the end portion on the side wall side of the beam plate portion 211. The saddle plate portion 213 is formed in parallel with the saddle plate portion 212. The rail-shaped beam plate portion 211 (an interposed member in the present invention) as a whole is supported at both ends by the side walls 21a and 21c, and itself is good for expansion and contraction of the magnetic coupling portion 6 in the column magnetic path direction. Therefore, the bending rigidity of the side walls 21b and 21d can be reduced. Moreover, manufacture of the metal case 21 can be facilitated while ensuring the heat conduction performance between the beam plate portion 211 and the side walls 21b and 21d. In addition, it is easy to press-fit the rail-shaped beam plate portion 211 between the side walls 21 b and 21 d and the magnetic coupling portion 6. However, it is preferable to inject mold resin thereafter.

(Sixth embodiment)
Another embodiment for reducing vibration in the direction of the magnetic pole of the reactor 1 and the metal case 21 will be described with reference to FIGS. 21 and 22. FIG. 21 is a schematic partial sectional view of the reactor device, and FIG. 22 is a schematic partial front view of the reactor device.

  In this embodiment, instead of providing the beam plate portion 211 inside the side walls 21b and 21d, a total of six beam plate portions 221 similar to the beam plate portion 211 are arranged outside the side walls 21b and 21d. In this way, the thickness direction bending rigidity of the side walls 21b and 21d can be strengthened in the same manner as described above, and vibrations in the column magnetic path direction of the reactor 1 can be suppressed, and each beam plate portion 221 functions as a radiation fin. Can be made.

It is a perspective view of the reactor of Embodiment 1. It is a front view of the reactor of Embodiment 1. It is a front view which shows a U-shaped core. It is a disassembled perspective view of a U-shaped core. It is a perspective view of a coil. It is a perspective view of a U-shaped half core. It is a disassembled perspective view of the reactor of Embodiment 1. FIG. It is an AA arrow directional cross-sectional view of the reactor of Embodiment 1. It is a partial front view of the DCDC converter for vehicles by which the reactor was mounted. It is a disassembled perspective view of the DCDC converter for vehicles by which the reactor was mounted. It is a characteristic view which shows the difference in coil temperature at the time of making the core side surface and coil side surface of a reactor close to a liquid cooling fin. It is a characteristic view which shows the difference in the temperature of each part of a reactor. It is a model front view of the reactor apparatus in 2nd Embodiment. It is a schematic cross section of the reactor apparatus in 2nd Embodiment. It is a typical fragmentary sectional view of the reactor apparatus in 3rd Embodiment. It is a model partial front view of the reactor apparatus in 3rd Embodiment. It is a model fragmentary sectional view of the reactor apparatus in 4th Embodiment. It is a model partial front view of the reactor apparatus in 4th Embodiment. It is a typical fragmentary sectional view of the reactor apparatus in 5th Embodiment. It is a model partial front view of the reactor apparatus in 5th Embodiment. It is a typical fragmentary sectional view of the reactor apparatus in 6th Embodiment. It is a model partial front view of the reactor apparatus in 6th Embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Reactor 2 B-shaped core 3 Coil 4 U-shaped core 5 Square column part 6 Magnetic coupling part 7 Bolt fastening hole 8 Spacer 9 Exposed magnetic path end surface 10 Coil part 10a Left side 10b Front side 10c Right side 11 Coil part 11b Front side 11c Left side 12 Start end portion 12a End portion 13 End portion 13a End portion 14 End portion 14a End portion 15 Start end portion 16 U-shaped half core 17 Resin coating portion 18 Sensor holding spacer 18A Groove portion 19 Linear taper surface 20 Spacer 21 Metal case 21a Side wall 22 Mold resin 23 Bottom surface 23a Step protrusion 24 Case hole 25 Liquid cooling type inverter device 26 Semiconductor card module 27 Liquid cooling fin 29 Cooling liquid inflow pipe 30 Cooling liquid outflow pipe 31 Converter housing 32 Temperature sensor 21a to 21d Side wall of metal case 21e Bottom plate of metal case 31a to 31d Side wall of converter housing 31e Bottom plate of converter housing 21f, 21g Stepped surface of metal case 211 Beam plate (rib)
212,213 Gutter plate part 221 Beam plate part

Claims (7)

A soft magnetic core having at least two column parts parallel to each other and a magnetic coupling part magnetically connecting the end parts to form a closed magnetic circuit;
A coil wound around the column;
A rectangular box-like case in which the core is accommodated and fixed;
With
The case is
A main sidewall that is disposed on both sides of the column portion in the magnetic path direction and extends substantially parallel to the magnetic coupling portion of the core;
A sub-side wall extending substantially parallel to the core column while being close to the column of the metal case;
Have
The column portion is
In the magnetic component that expands and contracts in the magnetic path direction by alternating current energization to the coil,
The magnetic component according to claim 1, wherein the main side wall has a bending rigidity in the thickness direction larger than that of the sub side wall and is in contact with the magnetic coupling portion of the core. The magnetic component according to claim 1,
The main sidewall is
A magnetic component characterized in that it is thicker than the sub-side wall. The magnetic component according to claim 1,
The main sidewall is
A magnetic component comprising reinforcing ribs extending toward the sub-side wall on both sides of the main side wall. The magnetic component according to claim 1,
The main sidewall is
A magnetic component comprising a protrusion protruding toward the magnetic coupling portion of the core and contacting the magnetic coupling portion. A soft magnetic core having at least two column parts parallel to each other and a magnetic coupling part magnetically connecting the end parts to form a closed magnetic circuit;
A coil wound around the column;
A rectangular box-like case in which the core is accommodated and fixed;
With
The case is
A main sidewall that is disposed on both sides of the column portion in the magnetic path direction and extends substantially parallel to the magnetic coupling portion of the core;
A sub-side wall extending substantially parallel to the core column while being close to the column of the metal case;
Have
The column portion is
In the magnetic component that expands and contracts in the magnetic path direction by alternating current energization to the coil,
A magnetic component comprising an interposed member that is supported by the main side wall and that contacts or couples to the magnetic coupling portion to restrict expansion and contraction of the core in the magnetic path direction of the column portion. The magnetic component according to claim 5, wherein
The interposed member is a magnetic component fixed to at least one of the main side wall and the magnetic coupling portion. The magnetic component according to claim 5, wherein
The interposed member is a magnetic component that is located between the main side wall and the magnetic coupling portion and extends in a magnetic path direction of the magnetic coupling portion.

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