JP2010003838A - Reactor device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problem, wherein in a conventional reactor device, manufacturing man-hours increase and the cost increases, caused by processes of extracting a reactor from a die, filling a resin in a reactor case, and curing of resin. <P>SOLUTION: In this reactor device 1 provided with a coil 12 which generates magnetic flux by carrying a current thereto, a core 13 acting as a magnetic path of the magnetic flux generated by the coil 12, and a resin 14 for fixing the coil 12, a molded case 11 for housing the coil 12, the core 13 and the resin 14 therein is housed inside the reactor case 30. The molded case 11 has projections 19 on its outer surfaces 16 and is such that the projections 19 contact the inner surface of the reactor case 30. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a reactor device in which a resin for fixing a coil is injected into a container.

A reactor is used in a DC-DC converter that boosts a battery used in a hybrid vehicle. The reactor includes a coil and a core, and a coil-sealed reactor that seals the coil with magnetic iron powder mixed resin is known from the viewpoint of insulation and heat resistance (see, for example, Patent Document 1). . Since the reactor generates heat during operation, it is desirable to dissipate heat to the outside by bringing a heat radiating member such as a heat sink into close contact. And if the shape of the heat radiating member which adhere | attaches a reactor is made into the housing | casing which the upper surface opened, it can radiate | emit heat not only from the bottom face but from the side face, and can efficiently radiate the reactor.
JP 2007-27185 A

  A resin is filled between the side surface of the reactor and the heat radiating member to fill the gap, but the thermal conductivity of the resin is not high. Furthermore, there is a problem that it takes time until the resin is cured, resulting in an increase in cost.

  An object of the present invention is to provide a reactor device that is excellent in heat dissipation and can be easily assembled.

  In the invention which concerns on Claim 1, In a reactor apparatus provided with the coil which generates magnetic flux by electricity supply, the core used as the magnetic path of the magnetic flux which the coil generate | occur | produced, and resin which fixes a coil, a coil, core, and resin are provided. A molding case that is accommodated inside and a reactor case that accommodates the molding case inside, and the molding case has a protrusion on the outer surface that contacts the inner surface of the reactor case.

  According to the present invention, since the projection of the molding case is in contact with the inner surface of the reactor case, heat can be radiated through the projection.

  Reactor manufacturing is easier than filling resin that is commonly used as heat dissipation material between the reactor and the reactor because the protrusion plays the role of a heat dissipation material by crushing the protrusion when housing the molded case in the reactor case. It can be performed. Specifically, the step of filling the resin and the step of curing the resin are not necessary.

  In addition, by projecting mainly at a place where heat dissipation is desired, a more accurate heat radiation design can be achieved than when a resin that flows during filling is used.

  Since the coil is sealed with resin in the molding case, insulation and waterproofness are improved, and heat can be diffused over a wide area of the molding case via the resin.

  In the invention which concerns on Claim 2, a shaping | molding case has a processus | protrusion in the bottom face part of an outer surface.

  According to the present invention, since the bottom surface portion of the outer surface has a large pressure when the molding case is accommodated, the protrusion can be easily crushed, and the assembling performance is improved.

  The invention according to claim 3 is characterized in that the number of protrusions per unit area of the protrusions increases as approaching the coil.

  According to the present invention, since many protrusions are provided as the coil that is the heat generation source is approached, it is possible to improve heat dissipation from the heat generation point.

  The invention according to claim 4 is characterized in that the shape of the protrusion increases as it approaches the coil.

  According to the present invention, since the shape of the protrusion is increased as it approaches the coil where heat generation is reduced, it is possible to improve heat dissipation from the heat generation point.

  The invention according to claim 5 is characterized in that the molding case has a protrusion on the side surface portion of the outer surface below the upper surface of the resin filled in the molding case.

  According to the present invention, since the protrusion is provided below the upper surface of the resin serving as the heat transfer medium, it is possible to improve the heat dissipation from the heat generation point.

  The invention according to claim 6 is characterized in that the number of protrusions provided on the side surface portion per unit area of the protrusion increases toward the upper surface of the resin.

  According to the present invention, since more protrusions are provided toward the upper surface of the resin that easily transfers heat, it is possible to improve heat dissipation.

  The invention according to claim 7 is characterized in that the protrusion provided on the side surface portion increases in shape toward the upper surface of the resin.

  According to the present invention, since the shape of the protrusion is increased toward the upper surface of the resin where heat is easily transmitted, the heat dissipation can be improved.

  The invention according to claim 8 is characterized in that the molded case has a recess engaging with the resin on the inner peripheral surface.

  According to the present invention, since the concave portion that engages with the resin is provided on the inner peripheral surface of the molding case, it is possible to prevent the reactor from being detached from the molding case.

  In the invention according to claim 9, the molded case has a screw hole in the central portion of the coil, and the reactor case has a fastening hole facing the screw hole on the bottom surface, and is fastened to the screw hole through the fastening hole. It is characterized by having the bolt which carries out.

  According to the present invention, since the molding case forms a screw hole in the central axis of the coil, it is possible to prevent the molding case from being detached from the reactor case while reducing the inhibition of the magnetic flux formation of the coil due to the screw hole formation. it can.

  The invention according to claim 10 is characterized in that the core is made of magnetic iron powder, and the core and the resin form a magnetic iron powder mixed resin in which the magnetic iron powder and the resin are mixed.

  By using the magnetic iron powder mixed resin, it is possible to prevent the magnetic flux from leaking to the outside.

  The invention according to claim 11 is characterized in that the reactor case, the protrusion, and the molded case are made of aluminum.

  According to the present invention, since aluminum having excellent malleability and ductility is used for the projection, the projection is easily deformed when the molded case is accommodated in the reactor case, and the reactor can be easily assembled.

  Moreover, heat dissipation can also be improved by adopting aluminum for the protrusion, the reactor case, and the molded case.

Example 1
FIG. 1 is a longitudinal sectional view of a molding case and a reactor case according to Embodiment 1 of the present invention, and FIG. 2 is a longitudinal sectional view of a reactor device according to Embodiment 1 of the present invention.

  The reactor device 1 includes a coil 12 that generates a magnetic flux when energized, a core 13 that is a magnetic path of the magnetic flux generated by the coil 12, and a resin 14 that seals and fixes the coil 12 to a molding case 11, and includes a reactor. It is formed by accommodating a molded case 11 that accommodates the coil 12, the core 13, and the resin 14 inside the case 30.

  In Example 1, the core 13 is made of magnetic iron powder, and the core 13 and the resin 14 form a dust core 15 (magnetic iron powder mixed resin) in which the core 13 and the resin 14 are mixed. The dust core 15 is filled inside and outside the coil 12. The magnetic iron powder used for the dust core 15 is soft ferrite powder exhibiting soft magnetism, and the resin 14 is an epoxy resin 14 having excellent heat resistance, insulating properties, and adhesiveness, polyphenylene sulfide (PPS), polybutylene terephthalate ( PBT) or the like is used.

  Further, as shown in FIG. 3, a laminated steel plate may be used as the core 13, and the resin 14 may be filled around the laminated steel plate and the coil 12.

  The molded case 11 accommodates the coil 12, the core 13, and the resin 14 therein, and the molded case 11 has protrusions 19 on the bottom surface portion 17 and the side surface portion 18 of the outer surface 16. The protrusion 19 may be formed only on one of the bottom surface portion 17 and the side surface portion 18. The protrusion 19 provided on the molding case 11 is deformed by the pressure from the reactor case side when the molding case 11 is press-fitted and accommodated in the reactor case 30. As a result, the protrusion 19 enters the gap between the molding case 11 and the reactor case 30. By providing the projections 19 on the outer surface 16 of the molded case 11, the heat dissipation path between the reactor case 30 and the molded case 11 can be surely aimed as compared with the case where the molded case 11 having a normal flat surface is adopted. Can be formed. Conventionally, a resin is used between the molded case 11 and the reactor case 30. However, since the resin flows, there is a problem that heat dissipation is reduced at a location where the resin stays thick. In the present invention, since the heat dissipation path between the cases is secured by the protrusion 19, the heat radiation path can be secured aiming at a location where the amount of heat generation is large. Furthermore, since the resin filling step and the resin curing step are not required, the assembly to the reactor case is simplified.

  The molded case 11, the protrusion 19, and the reactor case 30 are preferably made of a metal such as aluminum having excellent heat resistance and heat dissipation. In particular, the reactor case 30 is preferably made of a heat radiating member such as a heat sink.

  The reactor device 1 is formed by press-fitting and accommodating a molding case 11 in a reactor case 30. Since the molded case 11 is accommodated in the reactor case 30, the projection 19 of the molded case 11 is deformed by the pressure from the reactor case 30, and the projection 19 enters the gap between the molded case 11 and the reactor case 30. As a result, the projection 19 of the molding case 11 forms a heat dissipation path between the reactor case 30 and the molding case 11.

  The deformed protrusion 19 does not contact the entire inner surface 31 of the reactor case 30, but the heat from the coil 12 can be reduced by adopting a member having high thermal conductivity such as aluminum for the molding case 11 and the protrusion 19. Sufficient heat can be dissipated. Examples of metals having high thermal conductivity include copper and aluminum, and the thermal conductivity at room temperature is 390 W / (m · K) for copper and 236 W / (m · K) for aluminum. On the other hand, the thermal conductivity of the epoxy resin 14 generally used as a heat radiating material is 0.21 W / (m · K). Therefore, improvement of heat dissipation can be expected by adopting a metal as a medium for conducting heat between the reactor and the reactor case 30 and making the protrusion 19 have a structure capable of securing the contact area.

(Modification 1)
FIG. 4 shows a longitudinal sectional view of a molded case according to Modification 1 of the present invention.

  The molded case 11 has a protrusion 19 on the bottom surface portion 17 of the outer surface 16. As the projection 19 approaches the coil 12, the number per unit area increases, and in addition, the shape of the projection 19 increases as the coil 12 is approached. This is because a heat radiation path in a portion near the coil 12 that is a heat generation source can be reliably ensured. Further, as the distance from the heat source increases, the number of protrusions 19 may be reduced or the shape may be reduced. As a result, the pressure applied to the protrusions 19 provided near the heat generation source when the molded case 11 is accommodated in the reactor case 30 is increased, so that a heat radiation path can be reliably formed.

  Further, the molded case 11 may have a protrusion 19 on the side surface portion 18 of the outer surface 16 below the upper surface of the filled resin 14. In this case, the number of protrusions 19 on the side surface portion 18 per unit area increases toward the upper surface of the resin 14. In addition, the shape of the protrusion 19 of the side surface portion 18 increases as it goes toward the upper surface of the resin 14. With this configuration, it is possible to efficiently dissipate the heat near the top surface of the resin 14 through which heat is easily transmitted.

  As shown in the enlarged view (corresponding to the dotted line portion in FIG. 4) of the inner peripheral portion of the molding case 11 shown in FIG. 5, the molded case 11 has a recess 32 that engages with the resin 14 on the inner peripheral surface. Good. By providing the recess 32, it is possible to reduce the resin 14 from entering the recess 32 and the coil 12 sealed with the resin from being detached from the molding case 11.

(Modification 2)
FIG. 6 shows a reactor device 1 according to a modification of the present invention. In FIG. 5, the protrusion is omitted for simplicity. The molded case 11 has a screw hole in the central portion of the coil 12, and the reactor case 30 has a fastening hole 33 that faces the screw hole 21 in the bottom surface portion 17, and is a bolt that passes through the fastening hole and is fastened to the screw hole. 41. As a result, the fastening force between the molded case 11 and the reactor case 30 can be improved.

It is a longitudinal cross-sectional view of the shaping | molding case and reactor case which concern on Example 1 of this invention. It is a longitudinal cross-sectional view of the reactor case which concerns on Example 1 of this invention. It is a longitudinal cross-sectional view of the molding case which concerns on the modification of Example 1 of this invention. It is an enlarged view of the inner peripheral part of the reactor apparatus which concerns on the modification 1 of this invention. It is a modification of the reactor apparatus which concerns on the modification 1 of this invention. It is a longitudinal cross-sectional view of the reactor apparatus which concerns on the modification 2 of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Reactor apparatus 11 Molding case 12 Coil 13 Core 14 Resin 15 Dust core (magnetic iron powder mixed resin)
16 Outer surface 17 Bottom surface 18 Side surface 19 Protrusion 20 Resin upper surface 21 Screw hole 30 Reactor case 31 Inner surface 32 Recess 33 Fastening hole 41 Bolt

Claims (11)

In a reactor device comprising: a coil that generates a magnetic flux by energization; a core that is a magnetic path of the magnetic flux generated by the coil; and a resin that fixes the coil.
A molding case that houses the coil, the core, and the resin inside, and a reactor case that houses the molding case inside, and the molding case has a protrusion that contacts the inner surface of the reactor case on the outer surface. A reactor device characterized by comprising:   The reactor device according to claim 1, wherein the molding case has the protrusion on a bottom surface portion of the outer surface.   The reactor according to claim 1, wherein the number of the protrusions per unit area of the protrusions increases as the coil approaches the coil.   4. The reactor device according to claim 1, wherein the protrusion has a shape that increases as the coil approaches the coil. 5.   The reactor according to any one of claims 1 to 4, wherein the molding case has a protrusion on a side surface portion of the outer surface below the upper surface of the resin filled in the molding case. apparatus. As the protrusions provided on the side surface portion are directed toward the upper surface of the resin,
The reactor device according to claim 5, wherein the number of the protrusions per unit area increases. As the protrusions provided on the side surface portion are directed toward the upper surface of the resin,
The reactor device according to claim 5, wherein the shape of the protrusion becomes large.   The reactor device according to any one of claims 1 to 6, wherein the molding case has a concave portion that engages with a resin on an inner peripheral surface thereof.   The molded case has a screw hole in the central portion of the coil, and the reactor case has a fastening hole facing the screw hole in the bottom surface, and is fastened to the screw hole through the fastening hole. The reactor device according to claim 1, further comprising a bolt.   10. The core according to claim 1, wherein the core is made of magnetic iron powder, and the core and the resin form a magnetic iron powder mixed resin in which the magnetic iron powder and the resin are mixed. The reactor apparatus as described in any one.   The reactor device according to any one of claims 1 to 10, wherein the reactor case, the protrusion, and the molding case are made of aluminum.

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