JP2010245229A - Reactor device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To suppress the partially high temperature of a reactor core which is constituted of a plurality of members with gaps. <P>SOLUTION: A gap 54 to be filled with a filler is formed by prescribed amount W between the lower surface of an I shape core 44 with the reactor coil 50 wound therearound and the reactor coil 50. Consequently, when the reactor 30 is stored in a case 60, the filler to fill a gap 64 between the reactor 30 and the case 60 also fills the gap 54 between the I shape core 44 and the reactor coil 50. Then, heat to be generated in the I shape core 44 is radiated from the case 60 via the filler. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a reactor device.

  Conventionally, as this type of reactor device, the resin is filled in the gap between the reactor and the case for storing the reactor, and the reactor is stored in the case, or the reactor is cased by interposing a heat transfer sheet between the reactor and the case. Have been proposed (for example, see Patent Document 1). In these apparatuses, heat generated in the reactor is radiated from the case through the resin and the heat transfer sheet by such a configuration.

JP 2007-129146 A

  In the reactor device described above, when the core of the reactor has a gap (gap) in order to suppress magnetic saturation, the core may be partially heated. Since the core member wound around the coil is dissipated through the coating material for rust prevention and the gap between the core members, the heat dissipation efficiency becomes worse toward the center of the coil, and the core is partially May be hot.

  The reactor apparatus of this invention makes it the main objective to suppress that the reactor core comprised by a some member which has a gap partially becomes high temperature.

  The reactor device of the present invention employs the following means in order to achieve the main object described above.

The reactor device of the present invention is
A reactor core having two U-shaped cores and at least two I-shaped cores and formed in a flat donut shape as a whole, and a reactor coil wound around at least the I-shaped core In a reactor device comprising a reactor having a reactor and a case storing the reactor, the filler is filled in a gap between the reactor and the case, and the reactor is stored in the case.
The reactor is formed with a predetermined amount of a gap that can be filled with the filler between at least a lower surface of the I-shaped core and the reactor coil.
It is characterized by that.

  In the reactor device according to the present invention, the reactor is formed with a predetermined amount of gap that can be filled with a filler between the lower surface of the I-shaped core around which the reactor coil is wound and the reactor coil. As a result, when the reactor is stored in the case, the filler filled in the gap between the reactor and the case is also filled into a predetermined amount of gap between the I-shaped core and the reactor coil. The generated heat can be radiated from the case through the filler. Accordingly, it is possible to prevent the reactor core from being partially heated.

It is a perspective view which shows an example of the external appearance of the reactor apparatus 20 as one Example of this invention. It is the AA view which looked at the reactor 30 before storing in case 60 from the AA surface in FIG. FIG. 3 is an external view showing an external view of a rear anchor 40 viewed from above in FIG. 2.

  Next, the form for implementing this invention is demonstrated using an Example.

  FIG. 1 is a perspective view showing an example of an appearance of a reactor device 20 as an embodiment of the present invention. FIG. 2 shows a reactor 30 before being stored in a case 60 from the AA plane in FIG. FIG. 3 is an external view showing an appearance of the reactor core 40 viewed from above in FIG. 2. In FIG. 2, the case 60 is also shown by a one-dot chain line for easy understanding. As shown in FIG. 1, the reactor device 20 according to the embodiment includes a reactor 30 that constitutes a part of a boost converter mounted on a vehicle, for example, and a case 60 that stores and protects the reactor 30. 2 and 3, the reactor 30 includes a reactor core 40 formed in a flat donut shape as a whole, and a straight portion of the reactor core 40 (the entire I-shaped core 44 and a part of the U-shaped core 42). ) And a reactor coil 50 formed by winding a conductive wire, and formed of, for example, polyphenylene sulfide resin (PPS) to insulate the reactor core 40 from the reactor coil 50 and to prevent the reactor core 40 from being rusted. It is formed of a molding material 48 and a holder 52 having a fitting hole into which the bolt 62 is fitted and holding the reactor core 40 and the reactor coil 50. The reactor core 40 is composed of two U-shaped U-shaped cores 42 formed of dust cores and laminated steel plates, and three U-shaped cores 42 formed of a dust core and laminated steel plates in series. The non-magnetic (for example, ceramic) provided between the U-shaped core 42 and the I-shaped core 44 to suppress the power saturation of the reactor core 40 and the I-shaped I-shaped core 44 interposed therebetween. The gap 46 is formed. When the reactor 30 formed in this way is stored in the case 60, the reactor 30 is placed on the case 60 and the holder 52 is fastened to the case 60 using the bolts 62, and then the reactor 30 and the case 60 are connected. An insulating filler (for example, silicon resin) having a higher thermal conductivity than the mold material 48 is injected into the gap 64 to a height slightly lower than the height of the reactor 30.

  In the embodiment, as shown in FIG. 2, the molding material 48 includes a reactor except for a portion where the reactor coil 50 is wound on the lower surface of the reactor core 40 and a portion slightly outside the portion where the reactor coil 50 is wound. The reactor coil 50 is formed so as to cover the core 40, and the reactor coil 50 is a distance of a predetermined amount W (for example, several mm) between the portion of the lower surface of the reactor core 40 that is not covered with the molding material 48 and the reactor coil 50. It is wound with. Therefore, a gap 54 of a predetermined amount W is formed between the lower surface of the reactor core 40 and the reactor coil 50 before the reactor 30 is stored in the case 60. When the reactor 30 formed in this way is stored in the case 60, the filler is injected into the gap 64 between the reactor 30 and the case 60 as described above, so that the filler is filled in the gap 64 and the reactor core 40. The gap 54 formed between the portion of the lower surface not covered with the molding material 48 and the reactor coil 50 is also filled. By filling the gap 54 with the filler as described above, it is possible to secure insulation and prevent rust on the lower surface of the reactor core 40.

  Generally, it is desirable that the reactor 30 generates heat due to energization of the reactor coil 50 due to copper loss in the reactor coil 50, iron loss in the reactor core 40, and the like, and dissipates heat to suppress the temperature rise. Now, considering that the molding material 48 covers the entire lower surface of the I-shaped core 44, the I-shaped core 44 is radiated through the molding material 48, the gap 46, the U-shaped core 42, and the like. For this reason, the I-shaped core 44 has poor heat dissipation as compared with the U-shaped core 42 having a portion around which the reactor coil 50 is not wound, and the heat dissipation becomes worse toward the center of the reactor coil 50. As the reactor 30 generates heat, it may become partially hot. On the other hand, in the reactor device 20 of the embodiment, a gap 54 of a predetermined amount W is provided between the reactor coil 50 and the lower surface of the I-shaped core 44, and the gap 54 has a higher thermal conductivity than the molding material 48. Since the filler is filled, the I-shaped core 44 can be dissipated through the filler, and the mold material 48 covers the entire I-shaped core 44 and the I-shaped core 44 is dissipated through the mold 48. The heat dissipation of the I-shaped core 44 can be improved compared to what is made. Therefore, it is possible to prevent the reactor core 40 from partially reaching a high temperature.

  As described above, the reactor device 20 of the present invention described above forms the gap 54 of the predetermined amount W that can be filled with the filler between the lower surface of the reactor core 40 of the reactor 30 and the reactor coil 50. The filler filled in the gap 64 between the reactor 30 and the case 60 when being stored in the case 60 is also filled in the gap 54 between the I-shaped core 44 and the reactor coil 30, and heat generated in the I-shaped core 44 is generated. Heat can be radiated from the case 60 through the filler. Therefore, it is possible to prevent the reactor core 40 from being partially heated.

  The correspondence between the main elements of the embodiment and the main elements of the invention described in the column of means for solving the problems will be described. In the embodiment, a reactor core 40 having a U-shaped core 42 and an I-shaped core 44, and a reactor coil 50 wound around the reactor core 40, are formed between the lower surface of the reactor core 40 and the reactor coil 50. The reactor 30 provided with the gap 54 of the predetermined amount W that can be filled with the filler corresponds to the “reactor”, and the case 60 that stores the reactor 30 corresponds to the “case”.

  The correspondence between the main elements of the embodiment and the main elements of the invention described in the column of means for solving the problem is the same as that of the embodiment described in the column of means for solving the problem. Therefore, the elements of the invention described in the column of means for solving the problems are not limited. That is, the interpretation of the invention described in the column of means for solving the problems should be made based on the description of the column, and the examples are those of the invention described in the column of means for solving the problems. It is only a specific example.

  As mentioned above, although the form for implementing this invention was demonstrated using the Example, this invention is not limited at all to such an Example, In the range which does not deviate from the summary of this invention, it is with various forms. Of course, it can be implemented.

  The present invention can be used in the manufacturing industry of reactor devices.

  20 Reactor device, 30 Reactor, 40 Reactor core, 42 U-shaped core, 44 I-shaped core, 46 Gap 48 Mold material, 50 Reactor coil, 52 Holder, 54 Gap, 60 Case, 62 Bolt, 64 Gap.

Claims (1)

A reactor core having two U-shaped cores and at least two I-shaped cores and formed in a flat donut shape as a whole, and a reactor coil wound around at least the I-shaped core In a reactor device comprising a reactor having a reactor and a case storing the reactor, the filler is filled in a gap between the reactor and the case, and the reactor is stored in the case.
The reactor is formed with a predetermined amount of a gap that can be filled with the filler between at least a lower surface of the I-shaped core and the reactor coil.
A reactor device characterized by that.

Images