JP2008028288A - Reactor device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor device with reduced noise inexpensively as much as possible. <P>SOLUTION: The reactor device A includes: a reactor B having a core 1 and a coil 2; a case 3 for storing the reactor B; and a plate spring 6 interposed between the core 1 of the reactor B, and the case 3. The plate spring 6 is arranged at two corners of the case 3, generates biasing force in a direction inclined to a straight line section Ra of the core 1 by 45°, and attenuates nearly omnidirectional components of vibration generated by the core 1 for suppressing vibration. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to measures for reducing vibrations in a reactor device mounted mainly in a fuel cell vehicle, a hybrid vehicle, or the like.

  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 has a core formed by stacking a plurality of intermediate 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 intermediate partial cores sandwiching the gap, causing the reactor to vibrate. The reactor device is configured by housing a reactor in a case, but when reactor vibration propagates to the case, noise is emitted to the outside of the reactor device. In addition, the amount of heat generated inside the reactor device may increase due to the vibration of the reactor.

  Thus, how to reduce the vibration of the reactor 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 have been made to reduce the vibration of the reactor that leads to the noise of the reactor device. For example, Patent Document 1 discloses a technique for suppressing noise by interposing a vibration isolating material between divided partial cores in a reactor.

JP 2004-319679 A

  With the technique of the above-mentioned patent document 1, the effect of suppressing the vibration in the reactor due to the repeated generation and disappearance of the magnetic attractive force acting between the partial cores can be obtained to some extent. However, the insertion of an elastic vibration-proof material increases the dimensional change of the gap, thereby degrading the inductance adjustment accuracy. Therefore, the technique of Patent Document 1 has a problem that it can hardly be applied to a reactor that handles a high frequency of about 10 kHz.

  The objective of this invention is providing the reactor apparatus which has a structure which can reduce a vibration, maintaining the adjustment precision of an inductance highly.

  The reactor device of the present invention includes a reactor and a case that houses the reactor, and further includes at least one spring member that is connected to the case and biases the core of the reactor.

  Thereby, the adjustment accuracy of the inductance is not adversely affected, and the vibration of the core itself can be suppressed. Moreover, since the propagation of vibration from the core to the case is at least partially reduced, the generation of noise can also be suppressed.

  Since the spring member is installed in the corner portion of the case, an empty space can be used, so that it is possible to suppress vibration while avoiding an increase in the size of the reactor device.

  When the core has a straight portion, the direction of the urging force of the spring member is parallel to the straight portion of the core. Can be effectively suppressed.

  In particular, by having two spring members installed so that the direction of the urging force of the spring members oppose each other, there is almost no contact between the reactor and the case, so that the effect of propagation of the core vibration to the case is effective. Can be suppressed. Therefore, a large vibration suppressing function can be exhibited and a noise reduction effect can be expected.

  When the core has a straight portion, the spring member may be installed such that the direction of the urging force of the spring member intersects the straight portion of the core.

  By providing the two spring members installed so that the directions of the urging forces cross each other, the components in almost all directions of vibration can be suppressed. In particular, even when a relatively inexpensive sintered soft magnetic material is used as the core material instead of an expensive unstrained silicon steel plate, the vibration suppressing function can be exhibited.

  If the two spring members are installed at the corner of the case on one end side of the core, and the inclination angle from the core center line of the urging force of the spring member is the same, a bending moment is applied to the core. This is preferable in that an empty space can be used.

  In addition to the two spring members, a direct contact between the reactor and the case can be achieved by further arranging a spring member whose urging force is parallel to the linear portion of the core on the other end side of the linear portion of the core. Therefore, the propagation of vibrations to the case can be reliably suppressed, and a great noise reduction effect can be exhibited.

  In addition to the two spring members, the corner portion of the case on the other end side of the linear portion of the core further includes at least one spring member whose direction of the urging force intersects the linear portion of the core. The direct contact between the reactor and the case can be eliminated at all or very little, so that the propagation of vibration to the case can be surely suppressed and a great noise reduction effect can be exhibited. .

  Since the core is provided in a closed ring shape having two straight portions and two curved portions connecting the ends of the two straight portions, that is, in a track shape, the core has a structure suitable for a reactor.

  The spring constant of the spring member is preferably in the range of 30 to 500 N / mm in that the function as the spring member can be reliably exhibited.

  According to the reactor device of the present invention, by providing the spring member that urges the core of the reactor, it is possible to suppress the vibration of the reactor and to reduce the noise.

(Embodiment 1)
-Structure of the reactor device-
FIG. 1 is a perspective view showing a schematic configuration of reactor apparatus A in the first embodiment. As shown in the figure, the reactor apparatus A according to the present embodiment accommodates the core 1, the coil 2 that surrounds the core 1 in an annular shape, the middle case 4 that accommodates the core 1, the coil 2, and the like, and the entirety. Case 3, mounting jigs 7, 7 </ b> A arranged at the four corners of the case 3, and two leaf springs 6 inserted between the core 1 and the mounting jigs 7 </ b> A at the two corners. The X direction shown in FIG. 1 is a direction parallel to the linear portion Ra of the core 1, and is also the long side direction of the reactor device A whose planar shape is a rectangle. The Y direction shown in FIG. 1 is also a direction orthogonal to the straight line portion Ra of the core 1 and also a short side direction of the reactor device A. The mounting jig 7A in contact with the leaf spring 6 is a triangular shape having a hypotenuse whose planar shape is inclined by about 45 ° with respect to the X direction, and the mounting jig 7 on the opposite side has a substantially square planar shape. The attachment jigs 7 and 7A may be formed integrally with the case 3 by die casting or the like.

  FIG. 2 is a perspective view showing only the core in the embodiment. As shown in the figure, the core 1 has a substantially elliptical shape in plan view, two straight line portions Ra extending in the X direction, and a curve connecting the straight line portions Ra at both ends of the two straight line portions Ra. Part Rb. In addition, the core 1 includes side partial cores 12 and 12A that extend over the ends of the two linear portions Ra and the curved portion Rb, and intermediate partial cores that are alternately disposed between the side partial cores 12 and 12A in each linear portion Ra. 10 and a gap spacer 11. Of the two side partial cores 12 and 12A, one side partial core 12 has a curved corner portion, but the other side partial core 12A has a planar portion Rp formed in a planar shape. is doing. The flat surface portion Rp is not formed by cutting the curved surface portion of the conventional core 1 without the flat surface portion, but is a tangential plane of the curved surface portion, and is formed so as not to reduce the cross-sectional area of the core 1. Yes.

  The core 1 of the present embodiment has a structure suitable for a reactor for reducing a load during conversion between AC and DC in a high current and high frequency region, and is mounted on a hybrid vehicle or the like.

  FIG. 3 is a perspective view showing the shape of the leaf spring 6. As shown in the figure, the leaf spring 6 is bent from a substantially flat inner portion 6a, an outer portion 6b bent from the inner portion 6a and opposed to the inner portion 6a, and bent from the outer portion 6b in a substantially right angle direction. And an upper portion 6c extending to above the inner portion 6a.

  FIG. 4 is a schematic cross-sectional view showing the state of attachment of the leaf spring in the reactor device A. In order to make it easy to see, the reactor B is shown in a side view instead of a cross-sectional structure, but only a contact portion with the leaf spring 6 is shown in a cross-sectional structure. Further, illustration of members that are not main members such as the middle case 4 is omitted. 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 B to enter, and the core 1 (side partial cores 12, 12 </ b> A) of the reactor B is disposed on the inner surface of the case 3. It is supported in contact with the bottom surface. Although not shown, the case 3 is installed on the heat sink, and the heat generated in the reactor B 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.

  And as shown in FIG. 4, the inner part 6a of the leaf | plate spring 6 contact | abuts to the plane part Rp of 12 A of side part cores, the outer part 6b contact | abuts to the inner surface of case 3, and the upper part 6c is the side part core 12A. It is attached to cover a part. At this time, since the inner portion 6a and the outer portion 6b of the leaf spring 6 are bent in a direction approaching (compression spring), one leaf spring 6 biases the core 1 in a direction inclined 45 ° in the negative X direction. (See FIG. 1). The entire core 1 is urged in the X direction by the combined vector of the urging forces of the two leaf springs 6, and the entire core 1 is fixed in contact with the case 3. Further, by setting the inclination angle of the urging force of the leaf spring 6 from the core center line to be the same (in this embodiment, 45 °), the core 1 is stably held without applying a bending moment. be able to.

  FIG. 5 is a perspective view showing a part of the reactor B broken away in order to show the structure of the reactor B in detail. As shown in the figure, each linear portion Ra of the core 1 is covered with an inner bobbin 13 made of resin, and the coil 2 is wound around the outer side of the inner bobbin 13. A resin-made outer bobbin 15 is attached to both ends of the inner bobbin 13 and the coil 2. 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 that protrude upward from both ends. Has been. The coil 2 is almost entirely covered with an insulating film, and only a pair of terminals 23 are exposed from the insulating film. As described above, the coil 2 is configured by connecting the two annular portions 21 covering the respective linear portions Ra of the core 1 by the connection portion 22, and when energized, the two annular portions 21 are sequentially connected from one terminal 23. Then, an alternating current flows through the other terminal 23.

  FIG. 6 is a perspective view showing a part of the assembly procedure of reactor B. FIG. Assembly is performed according to the following procedure. First, after attaching the inner bobbin 13 so as to cover the outer periphery of the assembly in which the intermediate core 10 and the gap spacer 11 are bonded together, the inner bobbin 13 covers the space surrounded by the annular portions 21 of the coil 2. Each broken intermediate partial core 10 is fitted. At this time, the gap spacers 11 at both ends are exposed to the space in the annular portion 21 of the coil 2. Next, the two side partial cores 12 and 12A are attached so as to straddle the gap spacer 11 exposed at both ends of the assembly. Thereby, the assembly shown to the center part of FIG. 5 is assembled. Further, a closed annular core 1 is completed. Thereby, the reactor B is formed.

  After that, the outer bobbin 15 for fixing the side partial cores 12 and 12A and the coil 2 to each other is attached, the whole is housed in the middle case 4, and the reactor B housed in the middle case 4 is further housed in the case 3. Then, the leaf spring 6 is inserted as shown in FIG. In addition, after insertion of the leaf spring 6, the gap of the entire case 3 is filled with resin by potting with heating. At this time, almost the entire reactor A excluding the terminal 23 and a portion close to the terminal 23 is almost sealed in the resin.

-Material of each part of reactor device-
The side partial cores 12 and 12A and the intermediate partial core 10 of the core 1 are made of a soft magnetic material also called a high magnetic permeability material. Examples of soft magnetic materials include pure iron, soft iron, magnetic steel, silicon steel, permalloy, sendust, ferrite, and amorphous materials of magnetic alloys. A reactor that requires high frequency and high power, such as for driving an engine of a hybrid vehicle, is required to have a small iron loss in a frequency region of 1 kHz or higher. Moreover, in order to suppress vibration, it is preferable that the magnetostriction of the core 1 is small. As a soft magnetic material that meets such conditions, among non-oriented silicon steel plates, an unstrained silicon steel plate having about 6% silicon is frequently used because the magnetostriction is close to zero. However, this unstrained silicon steel sheet is expensive because it is expensive to manufacture.

  On the other hand, in the present embodiment, each of the side partial cores 12 and 12A and the intermediate partial core 10 of the core 1 is made of a sintered soft magnetic material. In this embodiment, as a sintered soft magnetic material, iron-based soft magnetic powder produced by an atomization method is surface-coated with a phosphate insulating coating and a resin binder, and the surface-coated powder is press-molded and then sintered at a high temperature. The result is used. This material has a low coercive force characteristic and is less expensive than an unstrained silicon steel sheet, but produces some magnetostriction compared to an unstrained silicon steel sheet.

  The gap spacer 11 is made of a nonmagnetic and insulating material such as ceramics, glass, or a glass epoxy substrate. The gap spacer 11 is a member necessary for adjusting the inductance according to the frequency. In addition, since the total thickness of the gap spacers 11 required for the core 1 as a whole is determined by design, the number of gap spacers 11 is set so that the thickness of one gap spacer 11 does not cause excessive leakage current. It has been established.

  The case 3 is made of a material having good thermal conductivity such as Cu or Cu alloy, aluminum or aluminum alloy, and is configured to release heat generated in the reactor B outward from the case 3. Yes.

  Examples of the material of the leaf spring 6 of the present embodiment include springs such as C steel, Si—Mo steel, Cr—Mo steel, Cr—Mn steel, Cr—Mn—B steel, Si—Cr steel, and SiCr—Mo steel. Spring alloys such as steel and phosphor bronze are used. And in order to suppress the vibration of a reactor reliably, it is preferable that the spring constant k exists in the range of 30-500 (N / mm).

-Operation of the reactor device-
When an alternating current flows through the coil 2 of the reactor B, the following action occurs in the core 1. Since the N pole and the S pole are generated at each end of the side partial core 12 and the intermediate partial core 10 in contact with the gap spacer 11, and the N pole and the S pole face each other with the gap spacer 11 interposed therebetween, the side partial core 12. In the middle partial core 10, a force to reduce the distance between each other, that is, a compressive force to the gap spacer 11 is generated. On the other hand, when the current to the coil 2 is interrupted, the compressive force on the gap spacer 11 disappears. By repeating this, vibration in the X direction is generated in the core 1. Further, the side partial core 12 and the intermediate partial core 10 of the core 1 are also distorted in directions other than the X direction due to the magnetostriction of the core 1, so that vibrations are generated not only in the X direction but also in each direction intersecting the X direction. When this vibration is transmitted to the case 3 or the like, the vibration is converted into noise.

  Therefore, it is important to take measures to reduce the vibration of the reactor. However, as described in Patent Document 1, using a vibration isolator as the gap spacer increases the dimensional change of the gap, so that the inductance adjustment accuracy deteriorates. To do. On the other hand, in the present embodiment, since a leaf spring as a spring member is interposed between the core 1 and the case 3 outside the core 1, the adjustment accuracy of the inductance is not adversely affected. Even if vibration occurs between the partial cores of the reactor, vibration in the X direction does not directly propagate to the case 3 due to the leaf spring 6 interposed between the core 1 and the case 3, so that the vibration of the case 3 It can be expected to reduce noise.

(Embodiment 2)
FIG. 7 is a perspective view showing a structure of reactor device A1 in the second embodiment. As shown in the figure, in the present embodiment, a leaf spring 6 as a compression spring is inserted at the center position of the two cores 1, that is, at the center position of the two short sides of the case 3. Since other structures are the same as those described in the first embodiment, the same reference numerals as those in the first embodiment are given and description thereof is omitted.

  Also in the present embodiment, since a leaf spring as a spring member is interposed between the core 1 and the case 3 outside the core 1, vibration is suppressed while maintaining the adjustment accuracy of the inductance. Can do. Further, since the propagation of the vibration of the core 1 to the case 3 is suppressed by the leaf spring 6, a noise reduction effect can be expected.

(Comparison of vibration suppression effect of Embodiments 1 and 2 and modification)
1. When there is only one leaf spring in the second embodiment (basic effect)
Even in that case, since a leaf spring as a spring member is interposed between the core 1 and the case 3 outside the core 1, vibration can be suppressed while maintaining the adjustment accuracy of the inductance. . Further, since it is possible to suppress only a part of the vibration of the core 1 from propagating to the case 3, it is possible to reduce noise. In particular, since the direction of the urging force of the leaf spring 6 is parallel to the linear portion Ra of the core 1, the attractive force between the partial cores (side partial cores 12, 12 </ b> A and the intermediate partial core 10) in the linear portion Ra of the core 1. It is possible to effectively suppress vibrations caused by repeated generation and disappearance of the water.

2. In the case where there is only one leaf spring in the first embodiment In this case, the leaf spring 6 can be disposed at the corner portion of the case 3, so that an increase in the size of the reactor device A can be avoided and a vibration suppressing effect can be exhibited. Can do. Further, since it is possible to suppress only a part of the vibration of the core 1 from propagating to the case 3, it is possible to reduce noise.

3. In the case of the second embodiment In this case, since the leaf springs 6 are arranged on both sides of the core, there is almost no direct contact between the core 1 and the case 3, so that the vibration of the core 1 propagates to the case 3. Can be effectively suppressed. Therefore, a large vibration suppressing function can be exhibited and a noise reduction effect can be expected. In addition, the leaf | plate spring 6 does not necessarily need to be arrange | positioned in the center of the short side part of 3 of a case. For example, the same effect can be exhibited even when the urging forces are arranged in two opposite corners and the directions of the urging forces are in a straight line and in opposite directions. However, in the case of the second embodiment, vibration due to repeated generation and disappearance of the attractive force between the partial cores can be more effectively suppressed.

4). In the case of Embodiment 1 The vibration between the partial cores occurs mainly in the central axis direction (X direction in FIG. 1) of the linear portion Ra of the core 1, but crosses the linear portion Ra of the core 1 due to the magnetostriction of the core. Vibration is also generated in the direction of the movement. In the case of a core using an unstrained silicon steel plate, since the magnetostriction is extremely small, it is only necessary to suppress the vibration in the X direction, which is the vibration between the partial cores. However, the unstrained silicon steel plate is disadvantageous in that it is expensive. . On the other hand, when a relatively inexpensive sintered soft magnetic material is used as in the first embodiment, vibrations other than in the X direction occur. Even in that case, by arranging the two leaf springs 6 in which the directions of the urging forces intersect each other, it is possible to suppress components in almost all directions of vibration. In addition, since the leaf spring 6 is installed in the corner portion of the case 3, the leaf spring 6 can be disposed in an empty space, so that an increase in the size of the reactor device A is avoided and vibration is suppressed. be able to. In particular, since the inclination angle between the direction of the urging force of each leaf spring 6 and the X direction is the same (45 °), no bending moment is applied to the core 1, so that the holding state of the core 1 is stabilized.

5. Modification 1
In the first modification, in addition to the two leaf springs 6 (see FIG. 1) of the first embodiment, one leaf spring that generates an urging force in the X direction is inserted into the central portion on the opposite side. In this case, in addition to the effects of the first embodiment, direct contact between the core 1 and the case 3 can be eliminated at all, so that the vibration of the core 1 can be effectively suppressed from propagating to the case 3. Therefore, a large vibration suppressing function can be exhibited and a noise reduction effect can be expected.

6). Modification 2
In the second modification, the leaf spring 6 of the first embodiment is also inserted into the opposite corner portion. In other words, the leaf springs 6 are inserted into the three or four corners of the case 3. In this case, almost all omnidirectional components of the vibration can be suppressed, and propagation of the vibration of the core 1 to the case 3 can be suppressed, and a larger vibration suppressing function can be exhibited. In addition, a noise reduction effect can be expected.

(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 each of the above embodiments and each modification, a leaf spring is used. However, the same effect as each of the above embodiments or each modification can be obtained by using a coil spring instead of the leaf spring or together with the leaf spring. Can be obtained.

  In each of the above-described embodiments and modifications, the leaf spring is inserted between the case and the core, but even if a spring member is inserted between the case and the cantilever whose base end is fixed to the case, The effect of embodiment and each modification can be maintained. In that case, it is also possible to increase the biasing force to the core by utilizing the lever principle.

  In each of the above embodiments and modifications, a compression spring is used, but in Embodiment 2, Modification 1 and Modification 2, a tension spring may be used. In that case, since the tensile force is always applied to the core 1, the action of suppressing the contraction force between the partial cores during energization occurs, and the vibration of the core 1 itself can also be suppressed.

  In the first embodiment, the flat surface portion Rp is provided on the side partial core 12A. However, even if the shape is the same as that of the opposite side partial core 12 without the flat surface portion Rp, the leaf spring 6 is brought into contact with and energized. It is possible. However, by providing the flat surface portion Rp, there is an advantage that the side partial core can be reliably prevented from being damaged and the holding state can be stabilized.

  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.

It is a perspective view which shows schematic structure of the reactor apparatus in Embodiment 1. FIG. FIG. 3 is a perspective view showing a structure of a core in the first embodiment. FIG. 3 is a perspective view showing a structure of a leaf spring in the first embodiment. It is sectional drawing of the reactor apparatus in Embodiment 1. FIG. FIG. 2 is a perspective view showing a structure of a reactor in the first embodiment. 5 is a perspective view showing a part of the assembly procedure of reactor B in the first embodiment. FIG. It is a perspective view which shows schematic structure of the reactor apparatus in Embodiment 2. FIG.

Explanation of symbols

A Reactor B Reactor 1 Core 2 Coil 3 Case 4 Middle case 6 Leaf spring 6a Inner part 6b Outer part 6c Upper part 7, 7A Mounting jig 10 Intermediate part core 11 Gap spacer 12, 12A Side part core 13 Inner bobbin 15 Outer bobbin 21 Ring portion 22 Connection portion 23 Terminal Ra Straight line portion Rb Curve portion Rp Plane portion

Claims (11)

A reactor having a core and a coil provided around the core;
A case for storing the reactor;
At least one spring member coupled to the case and biasing the core of the reactor;
Reactor device equipped with. The reactor device according to claim 1,
The reactor device, wherein the at least one spring member is disposed at a corner portion of the case. The reactor device according to claim 1 or 2,
The core has a straight portion;
The coil covers the straight portion of the core,
The reactor device, wherein the at least one spring member is installed so that a direction of an urging force thereof is parallel to the straight portion of the core. In the reactor apparatus in any one of Claims 1-3,
The reactor device is a reactor device in which the at least one spring member is two spring members installed so that the directions of the urging forces face each other. The reactor device according to claim 1 or 2,
The core has a straight portion;
The coil covers the straight portion of the core,
The reactor device, wherein the at least one spring member is installed so that a direction of an urging force intersects a straight portion of the core. The reactor device according to claim 1 or 2,
The reactor device is a reactor device in which the at least one spring member is two spring members installed so that directions of the urging forces intersect each other. The reactor device according to claim 6,
The two spring members are reactor devices installed at a corner portion of the case on one end side of the core. The reactor device according to claim 7,
A reactor device, further comprising a spring member disposed on the other end side of the linear portion of the core and installed so that the direction of the biasing force is parallel to the linear portion of the core. The reactor device according to claim 7,
A reactor further provided with at least one spring member installed at a corner portion of the case on the other end side of the linear portion of the core and installed so that the direction of the biasing force intersects the linear portion of the core apparatus. In the reactor apparatus in any one of Claims 1-9,
The core is provided in a closed ring shape having two straight portions and two curved portions connecting the ends of the two straight portions,
The said coil is a reactor apparatus which has two cylindrical parts which each cover the circumference | surroundings of the said two linear parts, and a connection part which connects the edge parts of these two cylindrical parts. In the reactor apparatus in any one of Claims 1-10,
The reactor device has a spring constant in a range of 30 to 500 N / mm.

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