JP2010129782A - Reactor, and power conversion apparatus incorporating the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor capable of preventing the propagation of oscillation, and a power conversion apparatus incorporating the same. <P>SOLUTION: The reactor 2 includes a winding part 211 prepared by winding around spirally a conductor line 210, a coil 21 for generating magnetic flux by carrying a current, while having a pair of taking-out parts 213 formed by having the conductor line 210 projecting out from winding ends 212 as the ends of the winding part 211 in the winding axis direction off the shape of the winding part 211, and a core 22 made of a magnetic powder mixing resin with a magnetic powder introduced disposed inside and outside of the coil 21. At least one taking-out part 213 of pairs of the taking-out parts 213 is formed so that a taking-out base end 214 formed adjacent to the winding end 212 are toward inside or outside of a projection region S formed by projecting the winding part 211 in the winding axis direction. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a reactor used for boosting an input voltage, and a power conversion device incorporating the reactor.

Conventionally, a reactor 9 that is used for boosting an input voltage and has a coil 92 and a core 93 as shown in FIGS. 10 and 11 is known (see, for example, Patent Document 1).
That is, as shown in FIG. 10A and FIG. 11, the coil 92 is a winding portion 921 formed by spirally winding the conductor wire 920 and a winding that is an end portion in the winding axis direction of the winding portion 921. It has a pair of extraction portions 922 formed by protruding the conductor wire 920 from the turning end portion 923, and generates a magnetic flux by energization.
As shown in FIG. 10 (b), the core 9 is made of a magnetic powder mixed resin that is arranged inside and outside the coil 92 and mixed with magnetic powder.

JP 2008-198981 A

  However, the conventional reactor 9 has the following problems. That is, the pair of extraction portions 922 are arranged in the direction of the winding axis from the winding end portion 923 in a projection area (see reference numeral S shown in FIG. 10A) formed by projecting the winding portion 921 in the winding axis direction. The conductor wire 920 protrudes in parallel with the wire. Specifically, the pair of extraction portions 922 are formed by protruding the conductor wire 920 from the winding end portions 923 on the opposite sides.

When the coil 92 is energized, the conductor wires 920 adjacent to each other in the winding axis direction of the winding portion 921 are attracted to each other (see the symbol f in FIG. 11). At this time, when the magnitude of the current supplied to the coil 92 changes, the force with which the adjacent conductor wires 920 pull each other changes, and the winding portion 921 vibrates in the winding axis direction. Here, particularly large vibrations occurred on the projection region S, and the vibrations generated in the winding part 921 were propagated to the pair of extraction parts 922 as they were.
Furthermore, the vibration has been transmitted to a power conversion device, a vehicle, or the like provided with the reactor 9 via a bus bar (not shown) electrically connected to the pair of extraction portions 922.

  The present invention has been made in view of such conventional problems, and an object of the present invention is to provide a reactor capable of suppressing the propagation of vibration and a power conversion device incorporating the reactor.

A first aspect of the present invention is the above-mentioned conductor from a winding end that is an end in the winding axis direction of the winding portion so as to deviate from the shape of the winding portion and a winding portion formed by winding a conductor wire in a spiral shape A coil that generates a magnetic flux by energization, and having a pair of extraction portions formed by projecting wires;
The coil is disposed inside and outside the coil, and has a core made of a magnetic powder mixed resin obtained by mixing magnetic powder,
At least one of the pair of extraction portions is a projection region in which an extraction base end portion formed adjacent to the winding end portion projects the winding portion in the winding axis direction. It is formed in the reactor characterized by going toward the inner side or the outer side (Claim 1).

The function and effect of the present invention will be described.
At least any one of the pair of extraction portions is formed such that the extraction base end portion is directed toward the inside or the outside of a projection region formed by projecting the winding portion in the winding axis direction. . Therefore, it is possible to provide a reactor that can suppress propagation of vibration generated in the winding part.
That is, when the magnitude of the current supplied to the coil changes, the force with which the adjacent conductor wires pull each other in the winding axis direction changes, and the winding portion vibrates in the winding axis direction. In particular, a relatively large vibration occurs on the projection area.

Therefore, if the extraction base end portion is formed so as to face the inside or the outside of the projection area as in the present invention, a portion where the influence of the vibration is relatively small, that is, the projection is avoided, avoiding the projection area where the vibration is greatly generated. At least one of the pair of extraction portions can be disposed inside or outside the region.
Thereby, it can suppress that the vibration which generate | occur | produced in the winding part propagates directly to the extraction part distribute | arranged inside or outside a projection area | region. Thereby, it can also suppress that the vibration propagates to the power converter etc. which incorporate the reactor of the present invention.

  As described above, according to the present invention, it is possible to provide a reactor that can suppress propagation of vibration.

  A second invention includes the reactor according to the first invention, a bus bar connected to the pair of extraction ends of the reactor, and a housing to which the reactor and the bus bar are fixed. (5).

  Since the power conversion device of the present invention has the reactor described in the first aspect of the invention, the vibration generated in the winding part is difficult to propagate to the pair of extraction parts and the bus bar connected thereto. There is almost no propagation to the device. Thereby, it can also suppress that a vibration propagates to the vehicle etc. provided with this power converter.

In the first invention, as the resin, for example, a thermosetting resin such as an epoxy resin, a thermoplastic resin, or the like can be used.
Moreover, as said magnetic powder, ferrite powder, iron powder, silicon alloy iron powder etc. can be used, for example.
Moreover, as said conductor wire, copper, aluminum, gold | metal | money, silver etc. can be used, for example.

In the first invention, it is preferable that at least one of the pair of extraction portions is formed such that the extraction base end portion faces the outside of the projection region. .
In this case, a sufficient magnetic flux can be formed to obtain a sufficient inductance, and a reactor capable of sufficiently suppressing the propagation of vibration can be obtained. That is, the density of the magnetic lines of force formed on the outside of the projection area is sparse compared to the inside. Therefore, by arranging any one of the pair of extraction portions outside the projection region, it is possible to sufficiently suppress the propagation of vibration without inhibiting the formation of magnetic field lines.

Moreover, it is preferable that both of said pair of extraction parts are formed so that each said extraction base end part faces the inner side or the outer side of the said projection area | region (Claim 3).
In this case, since both of the pair of extraction portions can be arranged in a portion where vibration is relatively small, it is possible to obtain a reactor that can further suppress vibration propagation.

Moreover, it is preferable that both of said pair of extraction parts are formed so that each said extraction base end part faces the outer side of the said projection area | region (Claim 4).
In this case, it is possible to obtain a reactor capable of obtaining a sufficient inductance and further suppressing vibration propagation.

Example 1
The Example which concerns on the reactor of this invention is described with FIGS.
The reactor 2 of this example includes the following coil 21 and core 22.

That is, as shown in FIG. 2, the coil 21 has a winding portion 211 formed by spirally winding the conductor wire 20 and an end portion in the winding axis direction of the winding portion 211 so as to deviate from the shape of the winding portion 211. And a pair of extraction portions 213 formed by protruding the conductor wire 210 from the winding end portion 212. The coil 21 generates a magnetic flux when energized.
As shown in FIGS. 1 and 3, the core 22 is arranged on the inside and outside of the coil 21 and is made of a magnetic powder mixed resin obtained by mixing magnetic powder.

  As shown in FIG. 2, the take-out base end 214 formed adjacent to the winding end 212 is located inside or outside the projection region S formed by projecting the winding 211 in the winding axis direction. At least one of the pair of extraction portions 213 is formed so as to face. In this example, the extraction base end portion 214 is formed so that both of the pair of extraction portions 213 face the outside of the projection region S.

Details will be described below.
The reactor 2 of this example can be disposed in a power converter 1 such as a DC-DC converter or an inverter and used for boosting the input voltage.
Specifically, the power conversion device 1 of this example is an inverter used for an automobile, for example.

First, the power converter device 1 of this example is demonstrated with FIG. 4, FIG.
In addition to the reactor 2, the power conversion device 1 includes a plurality of electronic components 12 and a plurality of cooling pipes 111 through which a cooling medium for cooling the plurality of electronic components 12 is circulated. Stacked cooler 11 that is alternately stacked, bus bar 131 that is electrically connected to connection terminal 120 of electronic component 12 to form a power line, and bus bar that is electrically connected to the pair of extraction portions 213 132 and a housing 14 that houses the reactor 2 and the stacked cooler 11 inside.

  In this example, the electronic component 12 may include an inverter element, for example. In particular, the electronic component 12 can be, for example, an inverter semiconductor module including an IGBT (power switching element) and an FWD (diode element).

  Such a semiconductor module for inverter can be used for various types such as an inverter for automobiles, a motor drive inverter for industrial equipment, and an air conditioner inverter for building air conditioning.

The electronic component 12 may be a battery (battery) in a hybrid electric vehicle (HEV) or an electric vehicle (EV), for example.
Further, unlike the above, the electronic component 12 may be a semiconductor that is not modularized. In such a case, for example, various components such as a thyristor, a power transistor, a power FET, and an IGBT can be used. .

  In this example, the cooling medium flowing in the cooling pipe 111 includes, for example, water mixed with ethylene glycol antifreeze, water, natural refrigerants such as ammonia, fluorocarbon refrigerants such as fluorinate, HCFC123, HFC134a, etc. Various refrigerants such as a fluorocarbon refrigerant, an alcohol refrigerant such as methanol and alcohol, and a ketone refrigerant such as acetone can be used.

The laminated cooler 11 cools the electronic component 12 from both main surfaces 121 thereof.
The laminated cooler 11 includes a plurality of cooling pipes 111 for sandwiching and cooling the electronic components 12 respectively.
The plurality of cooling pipes 111 are stacked and fixed by a refrigerant supply pipe 112 that supplies a cooling medium to the plurality of cooling pipes 111 and a refrigerant discharge pipe 113 that discharges the cooling medium from the plurality of cooling pipes 111.
Further, the cooling pipe 111 has an arrangement space 110 for arranging the electronic component 12.

  In this example, the electronic component 12 constitutes a part of an automotive inverter, and can be, for example, a semiconductor module incorporating an IGBT (power switching element) and an FWD (diode element).

Further, the electronic component 12 of this example is in direct contact with the cooling pipe 111. In addition to this, the electronic component 12 can be brought into contact with the cooling pipe 111 via an insulating material (ceramic plate or the like) or heat conductive grease.
The connection terminal 120 of the electronic component 12 and the bus bar 131 are in contact with each other to form a power line.

  As shown in FIG. 5, the end face 115 of the stacked cooler 11 is pressed in the stacking direction by the spring member 15, whereby the main surface 121 of the electronic component 12 and the cooling pipe 111 are in close contact with each other. It is configured as follows.

The housing 14 can have a substantially rectangular parallelepiped shape made of a light metal such as aluminum or a reinforced resin, for example.
In addition, the bus bar 132 electrically connected to the pair of extraction portions 213 of the reactor 2 is fixed to the housing 14 by, for example, bolts 262.
In addition, as shown in FIGS. 4 and 5, the reactor 2 of the present example includes a housing surrounded by the refrigerant supply pipe 112, the refrigerant discharge pipe 113, and the casing 14 (reactor case 23). It is fixed to the body 14.

In addition, the power converter device 1 of this example is not restricted to said shape and structure, It can form in various shapes and structures.
In addition, in FIGS. 4 and 5, for convenience of explanation, it is added that parts are simplified and various parts constituting the power converter 1 are omitted.

Next, the reactor 2 of this example is demonstrated with FIGS.
In addition to the coil 21 and the core 22 described above, the reactor 2 includes a reactor case 23 that is formed integrally with the casing 14 and accommodates the coil 21 and the core 22 inside itself as shown in FIG. Have.
As this reactor case 23, what consists of metals, such as aluminum excellent in heat dissipation, can be used, for example.

Further, as shown in FIG. 4, the reactor case 23 includes a substantially circular bottom surface portion 231 and a side surface portion 232 erected from the end edge toward one side.
An opening 233 having substantially the same shape as the reactor 2 is formed on one surface of the reactor case 23.
The reactor case 23 is not limited to the above-described configuration, but merely shows an example thereof.

Moreover, the reactor 2 has the substantially square-shaped cover part 25 which covers the opening part 233 of the reactor case 23, as shown in FIG.
The lid portion 25 has an opening hole 251 for inserting a pair of extraction portions 213 and a pair of handle portions 241 described later, and an opening hole 252 for inserting a fixing bolt 262.

  And the opening hole 251 for inserting a pair of extraction part 213 and the opening hole 251 for inserting a pair of handle part 241 are formed on the substantially same straight line, as shown in FIG. In particular, the opening holes 251 for inserting the pair of extraction portions 213 are formed in two portions of the four corners of the substantially rectangular lid portion 25. Furthermore, since two portions of the four corners of the lid portion 25 are portions corresponding to the dead space of the reactor case 23 (see reference sign D in FIGS. 4 and 5), a pair of take-outs in the dead space is provided. By arranging the portion 213, the space can be effectively used.

  In addition, as the magnetic powder mixed resin constituting the core 22, for example, magnetic powder such as ferrite powder, iron powder, silicon alloy iron powder or the like is used for thermosetting resin such as epoxy resin or resin such as thermoplastic resin. The mixed thing can be used.

As shown in FIG. 2, the conductor wire 210 constituting the coil 21 is made of, for example, flat rectangular copper.
The conductor wire 210 is wound, for example, in a spiral shape to form a substantially cylindrical winding portion 211.

In addition to the winding portion 211 described above, the coil 21 has a pair of extraction portions 213 formed by protruding the conductor wire 210 so as to be out of the shape of the winding portion 211 from the winding end portion 212.
Both of the pair of extraction portions 213 are formed such that each extraction base end portion 214 faces the outside of the projection region S formed by projecting the winding portion 211 in the winding axis direction. That is, the two extraction base end portions 214 are formed so as to deviate from the winding direction of the winding portion 211, that is, from a circular shape (see arrows X and Y in FIG. 2).
In addition, the pair of extraction portions 213 are both electrically connected to the bus bar 132 fixed to the housing 14 to constitute a power line.

The manufacturing procedure of the coil 21 will be briefly described with reference to FIG.
After the extraction portion 213a, which is the conductor wire 210, is formed so as to be bent at a right angle to the winding axis direction outside the portion to be the projection region S and to go into the projection region S, as shown in FIG. The winding part 211 is formed by winding the conductor wire 210.
Next, the conductor wire 210 is caused to jump out of the projection region S from the winding end 212b opposite to the winding end 212a where the extraction portion 213a is formed.

Next, the conductor wire 210 jumped out as described above is bent along the winding axis direction to form the other extraction portion 213b. Specifically, the conductor wire 210 is bent toward the side where the extraction portion 213a is formed.
The coil 21 can be manufactured by the above procedure.

Further, as shown in FIGS. 1, 3, and 4, the coil 21 is disposed so as to surround the periphery of the grip portion 24 that is insert-molded in the core 22.
That is, the grip portion 24 is inside the coil 21 and is formed, for example, from aluminum. A pair of handle portions 241 that grip the entire reactor 2 in a state of being embedded in the core 22 are formed on one end face of the grip portion 24.

Further, the grip portion 24 is formed with a fixed portion 242 for inserting the bolt 262 in the center thereof.
The bolt 262 is inserted through the fixed portion 242 through the lid portion 25, and the reactor 2 is fixed by fitting the bolt 262 to the fixed portion 235 formed on the bottom surface portion 231.
In this example, the reactor 2 is fixed in a state where the pair of extraction portions 213 are arranged on the diagonal line in the substantially rectangular opening 233 and outside the projection region S.

  In addition, although illustration is abbreviate | omitted, it is preferable that resin excellent in heat dissipation, such as a silicone resin and a urethane resin, is filled between the reactor 2 and the reactor case 23, for example. In this case, the heat of the reactor 2 can be sufficiently transmitted to the reactor case 23.

  The shape of the coil 21 is not limited to the above. That is, for example, as illustrated in FIG. 6, even if the extraction portion 213 a is not formed so that the extraction base end portion 214 a faces the projection region S, the projection region S is immediately formed from one end of the extraction base end portion 214 a. When the conductor wire 210 is bent toward the outside, it is possible to substantially prevent the vibration from propagating to the extraction portion 213a. Therefore, even such a configuration is included in the technical scope of the present invention.

Below, the effect of this example is demonstrated.
Both of the pair of extraction portions 213 are formed such that the extraction base end portion 214 faces the outside of the projection region S formed by projecting the winding portion 211 in the winding axis direction. Therefore, the reactor 1 which can suppress the propagation of the vibration generated in the winding part 211 can be provided.
That is, when the magnitude of the current supplied to the coil 21 changes, the force that the conductor wires 210 adjacent to each other in the winding axis direction attract each other changes, and the winding portion 211 vibrates in the winding axis direction. In particular, a relatively large vibration is generated on the projection region S.

Therefore, if the extraction base end portion 214 is formed so as to be directed to the outside of the projection region S as in this example, a portion where the influence of vibration is relatively small, avoiding the projection region S where vibration is greatly generated, that is, Both the pair of extraction portions 213 can be arranged outside the projection region S.
Thereby, it is possible to suppress the vibration generated in the winding part 211 from directly propagating to the extraction part 213 arranged outside the projection region S. Thereby, it can also suppress that the vibration propagates to the power converter device 1 etc. which incorporate the reactor 2 of this example.

  In the power conversion device 1 of this example, as described above, the vibration generated in the winding unit 211 is difficult to propagate to the pair of extraction units 213 and the bus bar 132 connected thereto. There is almost no propagation. Thereby, it can also suppress that a vibration propagates to the vehicle etc. which were equipped with this power converter device 1.

  As described above, according to this example, it is possible to provide a reactor that can suppress the propagation of vibrations, and a power converter that incorporates the reactor.

(Example 2)
In this example, as shown in FIGS. 7 and 8, one extraction portion 213a of the pair of extraction portions 213 is formed from the winding end portion 212a along the winding axis direction, and the other extraction portion 213b. Is an example of the reactor 2 in which the extraction base end portion 214 is formed so as to go to the outside of the projection region S from the winding end portion 212b.

Specifically, the extraction portion 213a is formed such that the extraction base end portion 214a extends from the winding end portion 212a along the winding axis direction.
On the other hand, the extraction portion 213b is formed in parallel with the winding axis direction after forming the extraction base end portion 214b from the winding end portion 212b opposite to the side where the extraction portion 212a is formed toward the outside of the projection region S. The conductor wire 210 is raised and formed so that
Other components and effects other than the shape of the extraction portion 213 are the same as those in the first embodiment.

(Example 3)
This example is an example of a reactor 2 in which a pair of extraction portions 213 are formed in a direction substantially orthogonal to the winding axis direction of the winding portion 211 as shown in FIG.
That is, in the coil 21, the conductor wire 210 (extraction portion 213 a) is allowed to enter the projection region S in a straight shape to form the winding portion 211, and then in the same direction as the direction in which the extraction portion 213 a is formed. An extraction portion 213b is formed by protruding the conductor wire 210 toward the surface.
Further, the reactor case 23 has a bottom surface portion 231 and a side surface portion 232 formed in a shape along a circular shape that is the shape of the winding portion 211.

  Further, unlike the first embodiment, the winding portion 211 is wound in a direction orthogonal to the opening direction of the opening portion 233 of the reactor case 23 (housing 14) and parallel to the stacking direction of the stacked cooler 11. The reactor 2 is housed in the reactor case 23 with the axial direction facing.

Then, the bolt 262 is fitted to the fixed portion 234 formed on the side surface portion 232, and the bolt 262 is inserted into the fixed portion 242 formed at the center of the grip portion 24 that is insert-molded inside the reactor 2. (Refer to the arrow Z in FIG. 9), the reactor 2 is fixed.
Other components and effects are the same as in the first embodiment.

The top view of a reactor in Example 1. FIG. The perspective view of the coil in Example 1. FIG. The perspective view of the reactor in Example 1. FIG. FIG. 3 is an exploded perspective view of the power conversion device according to the first embodiment. The top view of the power converter device in Example 1. FIG. The perspective view of the coil of another form in Example 1. FIG. The perspective view of the coil in Example 2. FIG. The perspective view of the reactor in Example 2. FIG. The expansion perspective view of the power converter in Example 3. FIG. (A) The perspective view of a coil in the prior art example, (b) The perspective view of a reactor. Explanatory drawing which shows the state in which the adjacent conductor wires have attracted in the prior art example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Power converter 11 Stack type cooler 111 Cooling pipe 12 Electronic component 132 Bus bar 2 Reactor 21 Coil 210 Conductor wire 211 Winding part 212 Winding end part 213 Takeout part 214 Takeout base end part 22 Core S Projection area

Claims (5)

A winding portion formed by winding a conductor wire in a spiral shape, and the conductor wire protruding from a winding end portion which is an end portion in the winding axis direction of the winding portion so as to deviate from the shape of the winding portion. A coil that has a pair of extraction portions and generates magnetic flux when energized;
The coil is disposed inside and outside the coil, and has a core made of a magnetic powder mixed resin obtained by mixing magnetic powder,
At least one of the pair of extraction portions is a projection region in which an extraction base end portion formed adjacent to the winding end portion projects the winding portion in the winding axis direction. It is formed so that it may face toward the inside or the outside of the reactor.   2. The reactor according to claim 1, wherein at least one of the pair of extraction portions is formed such that the extraction base end portion faces the outside of the projection region.   3. The reactor according to claim 1, wherein both of the pair of extraction portions are formed such that each of the extraction base end portions is directed toward an inner side or an outer side of the projection region.   4. The reactor according to claim 3, wherein each of the pair of extraction portions is formed such that each of the extraction base end portions faces the outside of the projection region.   It has the reactor as described in any one of Claims 1-4, the bus bar connected with the pair of said extraction end part of this reactor, The housing | casing to which the said reactor and the said bus bar are fixed, It is characterized by the above-mentioned. Power converter.

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