JP2018120957A - Coil device and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil device improved in heat dissipation and a shield effect.SOLUTION: A reactor 1 includes: a plurality of coils 5; a housing 9 for housing the coils 5; and a core 15 inserted into the inside of each coil 5. The entire inner peripheral surface and an area occupying the circumferential majority of an outer peripheral surface, in the entire axial direction of each coil 5 are covered with a magnetic body 13 having a thermal conductivity of 5 W/(m K) or more, without interposing air.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a coil device including a plurality of coils, a housing that houses the plurality of coils, and a core that is inserted into each of the plurality of coils, and a method for manufacturing the coil device.

  Patent Document 1 discloses a coil device including a pair of coils, a resin housing that houses the pair of coils, and a core made of a dust core that is inserted into each of the coils. . In this coil device, the housing is filled with a sealing resin for ensuring insulation, and by adding a heat conductive inorganic filler or the like to the sealing resin, a thermal conductivity of 1 to 2 W / ( m · K) to improve heat dissipation.

Japanese Patent Laying-Open No. 2015-95563

  However, in Patent Document 1, since the housing is filled with a sealing resin having a thermal conductivity of 1 to 2 W / (m · K), heat dissipation cannot be sufficiently improved. Further, when only a nonmagnetic material such as silicon nitride, which is usually used for increasing the thermal conductivity, is used as an additive for the sealing resin, a sufficient shielding effect for blocking electromagnetic waves cannot be obtained.

  This invention is made | formed in view of this point, The place made into the objective is to improve the heat dissipation of a coil apparatus, and the shielding effect.

  In order to achieve the above object, the present invention is characterized in that a magnetic material having a thermal conductivity of 5 W / (m · K) or more is employed as a coating material for the coil.

  Thereby, heat dissipation can be improved compared with the case where a coil is coat | covered with the nonmagnetic material which has the heat conductivity of 1-2 W / (m * K).

  Moreover, the shield effect which interrupts electromagnetic waves can be improved compared with the case where a coil is coat | covered with a nonmagnetic material.

  Specifically, an aspect of the first invention is a coil device including a plurality of coils, a housing that accommodates the plurality of coils, and a core that is inserted through each of the plurality of coils. A region occupying at least a part of the entire inner circumferential surface in the axial direction of each coil and a majority in the circumferential direction of the outer circumferential surface without interposing air with a magnetic material having a thermal conductivity of 5 W / (m · K) or more. It is characterized by being coated.

  As a result, the coil is coated with a magnetic material having a thermal conductivity of 5 W / (m · K) or more, and therefore the coil is coated with a non-magnetic material having a thermal conductivity of 1 to 2 W / (m · K). Compared with, heat dissipation can be improved.

  Further, since the coil is coated with the magnetic material without interposing air, the heat dissipation can be improved as compared with the case where air is interposed between the magnetic material and the coil.

  In addition, since the coil is coated with a magnetic material, the shielding effect for blocking electromagnetic waves can be enhanced as compared with the case where the coil is coated with a non-magnetic material.

  Further, in the above aspect, the magnetic body is filled without interposing air between the coils and the housing, and the entire interior of the coils is filled without air. You may make it comprise the core.

  Thereby, since the magnetic body is filled in the housing without interposing air, heat is easily transmitted from the magnetic body to the housing. Therefore, heat dissipation can be improved.

  Moreover, since the magnetic material is filled without interposing air between the coil and the housing, the coil is difficult to move. Therefore, it is possible to prevent the generation of abnormal noise due to vibration and the change in characteristics of the coil device.

  In addition, since a core member such as a dust core made of a member different from the magnetic body is not provided inside the coil, an operation of forming the core member and inserting it inside the coil becomes unnecessary. Therefore, the coil device can be easily manufactured.

  Moreover, in the said aspect, you may make it the magnetic permeability of the said magnetic body be 15-70 H / m.

  Thereby, compared with the case where the magnetic permeability of a magnetic body is less than 15 H / m, the shielding effect which interrupts | blocks electromagnetic waves can be improved more.

  Moreover, in the said aspect, you may make it the said housing comprise at least one of a heat conductive resin and a metal.

  Thereby, compared with the case where a housing is comprised with resin which does not have heat conductivity, a heat | fever is easily transmitted from a magnetic body to a housing. Therefore, heat dissipation can be improved.

  Further, in the above aspect, the plurality of coils may be provided so as to be adjacent to each other in the radial direction, and a spacer made of a nonmagnetic material may be interposed between the adjacent coils.

  Accordingly, by using a non-magnetic material that is cheaper than the magnetic material as the non-magnetic material constituting the spacer, the material cost of the coil device can be reduced by the amount that the magnetic material does not need to be filled in the spacer intervening portion.

  In the above aspect, the housing has an opening, and the magnetic body contains a magnetic material and a resin material made of at least one of an epoxy resin and an unsaturated polyester resin, A surface film may be formed on the opening side surface of the housing, and the ratio of the resin material in the surface film may be higher than that on the side opposite to the opening.

  Thereby, since the magnetic body on the side opposite to the opening of the surface film is covered with the surface film having a high ratio of the resin material, the magnetic body on the side opposite to the opening can be insulated by the surface film.

  In addition, the magnetic material is cured by pouring the liquid magnetic material containing the magnetic material and the resin material into the housing in a state where the coil is accommodated in the housing and the opening of the housing faces upward. Since the surface film can sometimes be formed of a resin material that has been lifted due to the difference in specific gravity, the surface film can be easily formed on the opening side surface of the magnetic body without separately preparing an insulating material for forming the surface film.

  Further, in the above aspect, the cross-sectional area passing through the axis of two of the plurality of coils of the magnetic body outside the coil in the axial direction is the area of the cross section perpendicular to the coil axial direction of the magnetic body inside the coil. You may make it be 0.6 to 1.5 times.

  As a result, the area of the cross section passing through the axis of two of the plurality of coils of the magnetic body on the outer side in the axial direction of the coil is set to 0. 0 of the area of the cross section perpendicular to the coil axis direction of the magnetic body on the inner side of the coil. The inductance change rate can be maintained in a suitable range as compared with the case of less than 6 times.

  The cross-sectional area passing through the axes of two of the plurality of coils of the magnetic body on the outer side in the axial direction of the coil is 1.5 times the area of the cross section perpendicular to the coil axial direction of the magnetic body on the inner side of the coil. Since the volume of the magnetic material can be reduced compared to the case where the value exceeds twice, the material cost of the magnetic material can be reduced.

  In the above aspect, the area of the cross section perpendicular to the coil axis direction of the magnetic body on the outer side in the circumferential direction of the coil is 0.2-1. You may make it be 5 times.

  As a result, when the area of the cross section perpendicular to the coil axis direction of the magnetic body on the outer side in the circumferential direction of the coil is less than 0.2 times the area of the cross section perpendicular to the coil axis direction of the magnetic body inside the coil. In comparison, the inductance change rate can be maintained in a suitable range.

  When the area of the cross section perpendicular to the coil axis direction of the magnetic body on the outer side in the circumferential direction of the coil exceeds 1.5 times the area of the cross section perpendicular to the coil axis direction of the magnetic body on the inner side of the coil In comparison with the above, the inductance change rate can be maintained in a suitable range, and the volume of the magnetic body can be reduced, so that the material cost of the magnetic body can be reduced.

  An aspect of the second invention is a method of manufacturing a coil device including a plurality of coils, a housing that houses the plurality of coils, and a core that is inserted through each of the plurality of coils. The plurality of coils are accommodated in the housing, and a liquid magnetic material containing a magnetic material and at least one of an epoxy resin and an unsaturated polyester resin is filled in the housing, and the magnetic material is cured in this state. Thus, a region that occupies at least a part of the entire inner circumferential surface in the axial direction of each coil and a majority in the circumferential direction of the outer circumferential surface is covered with the magnetic material made of the magnetic material without interposing air. To do.

  As a result, the coil is accommodated in the housing, and the magnetic material is formed by pouring the magnetic material into the housing to be cured, so a mold for magnetic material is prepared according to the shape of the magnetic material of the coil device to be manufactured. There is no need to do. Therefore, the manufacturing cost of the coil device can be reduced.

  According to the present invention, the heat dissipation and shielding effect of the coil device can be enhanced.

It is a perspective view of the reactor as a coil apparatus which concerns on Embodiment 1 in the state which is not filled with the magnetic body. It is sectional drawing corresponding to the II-II line | wire of FIG. 1 in the state filled with the magnetic body. It is sectional drawing corresponding to the III-III line | wire of FIG. 1 in the state filled with the magnetic body. It is sectional drawing corresponding to the IV-IV line | wire of FIG. 1 in the state filled with the magnetic body. A graph showing the relationship between the area of the cross section passing through the two coil axes of the magnetic body outside the coil in the axial direction of the coil, the ratio of the cross section area perpendicular to the coil axis direction of the magnetic body inside the coil, and the inductance change rate. is there. It is a graph which shows the relationship between the ratio of the area of the cross section perpendicular | vertical to the coil axial direction of the magnetic body of the outer peripheral direction of a coil, the area of the cross section perpendicular | vertical to the coil axial direction of the magnetic body inside a coil, and an inductance change rate. . It is a perspective view of the reactor as a coil apparatus which concerns on Embodiment 2. FIG. It is a top view of the reactor as a coil apparatus which concerns on Embodiment 2. FIG. It is sectional drawing in the IX-IX line of FIG. It is sectional drawing in the XX line of FIG. It is sectional drawing in the XI-XI line of FIG. It is a top view of a spacer. It is a front view of a spacer. FIG. 5 is a view corresponding to FIG. 4 showing a modification of the first embodiment.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
FIGS. 1-4 shows the vehicle-mounted reactor 1 as a coil apparatus which concerns on Embodiment 1 of this invention. The reactor 1 is attached to a metal heat radiating plate 3 having a fastening hole 3a. The reactor 1 is provided with a pair of coils 5 having substantially the same configuration so that their axial directions are parallel to each other and are adjacent to each other in the radial direction over the entire axial direction. Each coil 5 is formed of a round wire having a circular cross section, and includes a spiral winding portion 5a, a connecting portion 5b that connects both winding portions 5a, and an end portion 5c that is connected to a terminal fitting (not shown). Insulating treatment is performed by an epoxy resin mold or coating (not shown). Between these coils 5, a rectangular plate-like spacer 7 made of a non-magnetic material has its longitudinal direction oriented in the axial direction of both coils 5, and both the coils 5 are sandwiched from both sides in the plate thickness direction. The coil 5 is interposed over the entire longitudinal direction. The spacer 7 is made of a thermoplastic resin having high heat resistance, such as PPS (polyphenylene sanified resin).

  Each coil 5 and spacer 7 are accommodated in a housing 9 made of box-shaped aluminum. The housing 9 has a bottom surface portion 9a having a rectangular shape in plan view and a peripheral wall portion 9b protruding from the outer peripheral edge of the bottom surface portion 9a, and an opening 9c is formed at the distal end side of the peripheral wall portion 9b. Has been. A plurality of positioning projections 9 d are provided on the inner surface of the bottom surface portion 9 a of the housing 9 so as to be spaced apart from each other in the axial direction of the coil 5. Each coil 5 and spacer 7 are in contact with the positioning projection 9d from the opening 9c side. Further, the opposing direction of both the coils 5 (the plate thickness direction of the spacer 7) coincides with the opposing direction of a pair of opposing surfaces (upper and lower surfaces in FIG. 2) of the peripheral wall portion 9b. A mounting piece 9f having a through hole 9e is projected from the outer surface of the peripheral wall 9b. The housing 9 is fastened in a state where the outer surface of the bottom surface portion 9a is in contact with the heat radiating plate 3 by inserting the screw 11 through the through hole 9e of the attachment piece 9f of the housing 9 and the fastening hole 3a of the heat radiating plate 3. It is attached by. 1 and 2, the configuration around the attachment piece 9f is not shown.

  Further, between the coil 5 and the spacer 7 and the housing 9, a magnetic body 13 having a thermal conductivity of 5 W / (m · K) or more and a magnetic permeability of 15 H / m or more and 70 H / m or less interposes air. Instead, it is continuously filled throughout. Therefore, the magnetic body 13 covers the entire end surfaces of the coil 5, the entire inner peripheral surface, and the entire region excluding the spacer 7 contact portion and the positioning projection 9d contact portion on the outer peripheral surface without air interposed therebetween. ing. The magnetic body 13 covers a region that occupies a majority in the circumferential direction of the entire outer circumferential surface in the axial direction of the coil 5. The magnetic body 13 also fills the entire inside of the coil 5, and a core 15 is formed in which the portion of the magnetic body 13 filled in the coil 5 is inserted into the coil 5. Here, the thermal conductivity of the magnetic body 13 is preferably 5 to 7 W / (m · K), and particularly preferably 5.5 W / (m · K) to 6.5 W / (m · K). Moreover, 15-70 H / m is preferable and, as for the magnetic permeability of the magnetic body 13, 20-50 H / m is especially preferable. Moreover, the magnetic body 13 contains a magnetic material and a resin material made of an epoxy resin. The magnetic material is preferably 90 parts by weight or more and the resin material is preferably 10 parts by weight or less with respect to 100 parts by weight of the magnetic body 13. Permalloy, permendur, and soft ferrite can be used as the magnetic material, and preferably an iron-based metal such as Fe-Si alloy, Fe-Al alloy, Sendust, amorphous magnetic alloy, or nanocrystal magnetic alloy is used. Can do. A surface film 13a is formed on the surface of the housing 9 of the magnetic body 13 on the opening 9c side, and the content of the resin material in the surface film 13a is higher than that on the side opposite to the opening 9c. The area of the cross section passing through the axes of the two coils 5 of the magnetic body 13 on the outer side in the axial direction of the coil 5 (the area of the area marked with dots in FIG. 2) is perpendicular to the axial direction of the coil 5 of the magnetic body 13 on the inner side of the coil 5. It is 0.6 to 1.5 times as large as the cross-sectional area (the area of the rough dotted area in FIG. 4). The area of the cross section perpendicular to the coil 5 axis direction of the magnetic body 13 on the outer side in the circumferential direction of the coil 5 (the area of the area dotted in FIG. It is 0.2 to 1.5 times the area of the vertical cross section (the area of the region with coarse dots in FIG. 4). In FIG. 2, the symbol D is a line indicating the direction of the magnetic flux when current is passed through both the coils 5.

  Here, the manufacturing method of the reactor 1 comprised as mentioned above is demonstrated.

  First, the coils 5 and the spacers 7 are placed on the positioning projections 9d of the housing 9 with the opening 9c of the housing 9 facing upward. In this state, a liquid magnetic material containing the magnetic material and the resin material is poured into the housing 9 to be filled, and is pressurized and cured under vacuum. At this time, the resin material rises due to the specific gravity difference, and the raised resin material constitutes the surface film 13a. Thereby, the magnetic body 13 is formed between the coil 5 and the spacer 7 and the housing 9. Therefore, the magnetic body 13 covers the entire end surfaces of the coil 5, the entire inner peripheral surface, and the entire region excluding the spacer 7 contact portion and the positioning projection 9 d contact portion on the outer peripheral surface without interposing air. At the same time, the entire interior of the coil 5 is filled.

  In this way, the magnetic body 13 is formed by housing the coil 5 in the housing 9 and pouring the magnetic material into the housing 9 to be cured, so that the magnetic body is formed according to the shape of the magnetic body 13 of the reactor 1 to be manufactured. There is no need to prepare 13 molds, and there are no design restrictions resulting from mold forming. Therefore, the degree of freedom regarding the shape design of the magnetic body 13 can be increased, and the manufacturing cost of the reactor 1 can be reduced.

  Further, since the resin material that floats when the magnetic material is cured constitutes the surface film 13a, the surface film is formed on the surface of the magnetic body 13 on the opening 9c side without separately preparing an insulating material for forming the surface film 13a. 13a can be formed easily.

  Therefore, according to the first embodiment, since the coil 5 is coated with the magnetic body 13 having a thermal conductivity of 5 W / (m · K) or more, a resin having a thermal conductivity of 1 to 2 W / (m · K) is used. Compared with the case where it coat | covers, heat dissipation can be improved.

  Further, since the coil 5 is covered with the magnetic body 13 without interposing air, the heat dissipation can be improved as compared with the case where air is interposed between the magnetic body 13 and the coil 5.

  Further, since the coil 5 is covered with the magnetic body 13 without interposing air, and the covered portion of the coil 5 is made difficult to move, it is possible to prevent the generation of abnormal noise due to vibration and the change in the characteristics of the reactor 1.

  In addition, since the coil 5 is coated with the magnetic body 13 having a permeability of 15 H / m or more, the shielding effect for blocking electromagnetic waves can be enhanced as compared with the case where the coil 5 is coated with a non-magnetic body.

  In addition, since the coil 5 is coated with the magnetic body 13 having a permeability of 15 H / m or more, the magnetic flux leakage caused by housing the coil 5 in the aluminum housing 9 is suppressed, and the inductance caused by the magnetic flux leakage is suppressed. Decline can be prevented.

  In general, the nonmagnetic material constituting the spacer 7 is less expensive than the material of the magnetic body 13, and therefore, compared with the case where the spacer 7 is not provided, the magnetic body 13 does not need to be filled in the spacer 7 interposed portion. The material cost of the reactor 1 can be reduced. Further, since the spacer 7 is made of a non-magnetic material, magnetic flux leakage is suppressed, and a decrease in inductance due to magnetic flux leakage can be prevented.

  Further, since the housing 9 made of aluminum is filled with the magnetic body 13, heat is more easily transmitted from the magnetic body 13 to the housing 9 than when the housing 9 is made of a resin having no thermal conductivity. Therefore, heat dissipation can be improved.

  Moreover, since the magnetic body 13 is filled in the housing 9 without interposing air, the heat dissipation can be improved as compared with the case where air is interposed between the magnetic body 13 and the housing 9.

  Moreover, since the magnetic body 13 is filled without interposing air between the coil 5 and the housing 9, the coil 5 is difficult to move. Therefore, it is possible to prevent the generation of abnormal noise due to vibration and the change in the characteristics of the reactor 1.

  Further, since the magnetic body 13 on the side opposite to the opening 9c of the surface film 13a is covered with the surface film 13a having a high resin material ratio, the magnetic body 13 on the side opposite to the opening 9c can be insulated by the surface film 13a. .

  Moreover, since the core member and spacer member which are members different from the magnetic body 13 are not provided inside the coil 5, the operation of forming the core member or spacer member and inserting it inside the coil 5, or the core member and spacer The operation | work which assembles a member mutually becomes unnecessary. Therefore, the reactor 1 can be easily manufactured.

  Moreover, since the magnetic body 13 is continuously filled to form the core 15 and no adhesive layer for adhering a plurality of core members is provided, variation in characteristics of the two coils 5 can be suppressed.

  The area of the cross section passing through the two coil 5 axes of the magnetic body 13 on the outer side in the axial direction of the coil 5 is 0.6 times or more of the area of the cross section perpendicular to the axial direction of the coil 5 of the magnetic body 13 on the inner side of the coil 5. Therefore, as shown in FIG. 5, the inductance change rate can be maintained in a suitable range as compared with the case of less than 0.6 times. Here, in FIG. 5, X is defined as shown in the following Expression 1.

  X = (Area of the cross section passing through the axes of the two coils 5 of the magnetic body 13 outside the coil 5 in the axial direction) / (Area of the cross section perpendicular to the axis of the coil 5 of the magnetic body 13 inside the coil 5) (Formula 1)

  Further, in FIG. 6, X is defined as shown in the following formula 2.

  X = (area of the cross section perpendicular to the coil 5 axis direction of the magnetic body 13 on the outer side in the circumferential direction of the coil 5) / (area of the cross section perpendicular to the coil 5 axis direction of the magnetic body 13 on the inner side of the coil 5) ( Formula 2)

  5 and 6, the inductance change rate Y is obtained by the following equation 3 when the inductance when X = 1 is a reference value and the inductance when X is set to each value is a measured value. It is done.

  Y = {(measured value−reference value) / reference value} × 100 (%) (Equation 3)

  The area of the cross section passing through the two coil 5 axes of the magnetic body 13 on the outer side in the axial direction of the coil 5 is 1.5 times or less than the area of the cross section perpendicular to the axial direction of the coil 5 of the magnetic body 13 on the inner side of the coil 5. As a result, the rate of change in inductance can be maintained in a suitable range and the volume of the magnetic body 13 can be reduced, and the material cost of the magnetic body 13 can be reduced, compared to the case where the value exceeds 1.5 times. .

  Further, the area of the cross section perpendicular to the coil 5 axis direction of the magnetic body 13 on the outer side in the circumferential direction of the coil 5 is 0.2 times or more of the area of the cross section perpendicular to the coil 5 axis direction of the magnetic body 13 inside the coil 5. Therefore, as shown in FIG. 6, the inductance change rate can be maintained in a suitable range as compared with the case of less than 0.2 times.

  The area of the cross section perpendicular to the coil 5 axial direction of the magnetic body 13 on the outer side in the circumferential direction of the coil 5 is 1.5 times or less than the area of the cross section perpendicular to the coil 5 axial direction of the magnetic body 13 inside the coil 5. Therefore, compared with the case where the value exceeds 1.5 times, the inductance change rate can be maintained in a suitable range, the volume of the magnetic body 13 can be reduced, and the material cost of the magnetic body 13 can be reduced.

(Embodiment 2)
FIGS. 7-11 shows the reactor 1 as a coil apparatus which concerns on Embodiment 2 of this invention. In the second embodiment, the reactor 1 is provided with three coils 5. The axes X1 of these three coils 5 are arranged at the same distance from the predetermined center axis X2 parallel to the axis X1 and at equal intervals in the circumferential direction of the center axis X2. 12 and 13, the spacer 7 includes a cylindrical shaft portion 7a extending in the direction of the central axis X2 around the central axis X2, and an outer peripheral surface of the shaft portion 7a in the circumferential direction. It is composed of three substantially plate-like projecting plate portions 7b that project from regions excluding both ends in the longitudinal direction in three regions divided into three equal parts. The front and back surfaces of each protruding plate portion 7b are curved so as to form an arc shape when viewed from both longitudinal sides of the shaft portion 7a. And each protrusion board part 7b of the spacer 7 interposes between a pair of adjacent coils 5, and the both surfaces contact | abut to the area | region of the circumferential direction substantially 1/6 in the outer peripheral surface of each coil 5 over the whole. I am letting. In addition, the peripheral wall portion 9b of the housing 9 surrounds the three coils 5 and the spacer 7 with a certain interval from the outer circumferential side to the entire periphery, and the outer peripheral edge of the bottom wall portion 9a of the housing 9 The shape corresponds to the cross-sectional shape of the peripheral wall portion 9b. A plurality of positioning projections 9 d are provided on the outer peripheral portion of the inner surface of the bottom surface portion 9 a of the housing 9 so as to protrude in the circumferential direction of each coil 5. Each coil 5 is in contact with the positioning projection 9d from the opening 9c side. And between the three coils 5 and the spacer 7, and the surrounding wall part 9b, the magnetic body 13 is filled with a fixed width without a gap. Therefore, the magnetic body 13 covers the entire both end surfaces of the coil 5, the entire inner peripheral surface, and the entire region excluding the contact portion of the spacer 7 on the outer peripheral surface without interposing air. In addition, one end in the longitudinal direction of the shaft portion 7 a of the spacer 7 protrudes from the surface on the opening 9 c side of the magnetic body 13, and the other end in the longitudinal direction of the shaft portion 7 a of the spacer 7 is the inner surface of the bottom wall portion 9 a of the housing 9. Abut.

  Also in the second embodiment, the area of the cross section passing through the axes of the two coils 5 among the three coils of the magnetic body 13 on the outer side in the axial direction of the coil 5 (the area of the area marked with dots in FIG. 11) 5 is 0.6 to 1.5 times the area of the cross section perpendicular to the coil 5 axis direction of the magnetic body 13 inside (the area of the region roughly dotted in FIG. 9). Moreover, the area of the cross section perpendicular to the coil 5 axial direction of the magnetic body 13 on the outer side in the coil 5 direction (the area of the area marked with dots in FIG. 9) is the axial direction of the magnetic body 13 on the inner side of the coil 5 in the coil 5 axis direction. It is 0.2 to 1.5 times the area of the cross section perpendicular to the area (the area of the roughly dotted area in FIG. 9).

  Since the structure and manufacturing method of the other reactor 1 are the same as Embodiment 1, the same code | symbol is attached | subjected to the same structure location and the detailed description is abbreviate | omitted.

  Therefore, according to the second embodiment, since the spacer 7 made of a nonmagnetic material is interposed between the adjacent coils 5, magnetic flux leakage generated between the adjacent coils 5 can be suppressed.

  In the first and second embodiments, the spacer 7 is a separate member from the housing 9, but the spacer 7 may be formed integrally with the housing 9 as shown in FIG. In such a configuration, if both the spacer 7 and the housing 9 are integrally formed using a metal such as aluminum, heat dissipation can be improved.

  In the first and second embodiments, the entire inner circumferential surface of the coil 5 in the entire axial direction and the area occupying the majority in the circumferential direction of the outer circumferential surface are covered with the magnetic body 13. You may make it coat | cover the area | region which occupies the circumferential direction majority of the whole surrounding surface and an outer peripheral surface with the magnetic body 13. FIG.

  In the first and second embodiments, the entire housing 9 is made of aluminum, but aluminum alloy, magnesium and its alloy, copper and its alloy, silver and its alloy, iron and its alloy, austenitic stainless steel, etc. You may comprise with another metal. Moreover, you may comprise with heat conductive resin formed by adding a heat conductive filler etc. to resin, such as PA (polyamide resin), PPS, PBT (polybutylene terephthalate resin), and polycarbonate. Moreover, you may comprise the housing 9 whole with two layers, the metal layer which consists of metals, and the resin layer which consists of heat conductive resin. Thereby, compared with the case where the whole housing 9 is comprised with a metal, the usage-amount of a metal reduces, Therefore When using a metal more expensive than a heat conductive resin, material cost can be reduced. When the inner layer of the entire housing 9 is a resin layer and the outer layer is a metal layer, that is, when the outer surface of the housing 9 is made of metal, the outer surface of the housing 9 is made of resin. Compared to the case, heat is easily transferred from the outer layer of the housing 9 to the metal heat radiating plate 3, so that the heat radiating effect can be enhanced.

  Further, only a part of the housing 9 including the abutting portion with the heat radiating plate 3 is a heat radiating portion having at least an outer surface made of metal, and a portion other than the heat radiating portion in the housing 9 is heated over the entire thickness direction. You may comprise with conductive resin.

  In the first and second embodiments, the resin material contained in the magnetic body 13 is an epoxy resin. However, the resin material may be an unsaturated polyester resin or both an epoxy resin and an unsaturated polyester resin.

  Further, in Embodiments 1 and 2, the entire inside of the coil 5 is filled with the magnetic body 13, but a core member made of a member different from the magnetic body 13 may be disposed inside the coil 5. As the core member, for example, an integrally molded product of powder magnetic material containing metal magnetic powder can be used. Thereby, since it is not necessary to fill the entire inside of the coil 5 with the magnetic material, the filling work of the magnetic material is facilitated as compared with the case where the entire inside of the coil 5 is filled with the magnetic material. Further, by adopting a material that is cheaper than the material of the magnetic body 13 as the material of the core member, the material cost of the reactor 1 can be reduced as compared with the case where the entire interior of the coil 5 is filled with the magnetic body 13.

  In the first and second embodiments, the spacer 7 is made of a thermoplastic resin, but may be made of a nonmagnetic metal material.

  In the first and second embodiments, the coil 5 is a round wire wound coil. However, the present invention is not limited to this, and other known coils such as a flat wire flat wound coil and a flat wire edgewise coil are used as the coil 5. Can do.

  In the first and second embodiments, the magnetic material is pressurized and cured under vacuum, but may be cured at normal pressure. However, as a method for curing the magnetic material, a method of applying pressure in vacuum is most preferable.

  In the first and second embodiments, the magnetic material is poured into the housing 9 after the coil 5 is placed in the housing 9. However, after the magnetic material is poured into the housing 9, the coil 5 is put into the housing 9. You may do it.

  Moreover, in the said Embodiment 1, 2, although this invention was applied to the vehicle-mounted reactor 1, this invention is applicable also to coil apparatuses of other uses, such as for power conditioners.

  INDUSTRIAL APPLICABILITY The present invention is useful as a coil device including a plurality of coils, a housing that accommodates the plurality of coils, and a core that is inserted through each of the plurality of coils, and a method for manufacturing the coil device.

1 Reactor (coil device)
5 Coil 7 Spacer 9 Housing 9c Opening 13 Magnetic body 13a Surface film 15 Core

Claims (9)

A coil device comprising a plurality of coils, a housing that houses the plurality of coils, and a core that is inserted through each of the plurality of coils,
A region occupying at least a part of the entire inner circumferential surface in the axial direction of each coil and a majority in the circumferential direction of the outer circumferential surface without interposing air with a magnetic material having a thermal conductivity of 5 W / (m · K) or more. Coil device characterized by being covered. The coil device according to claim 1,
The magnetic body is filled between the coils and the housing without interposing air, and the entire interior of the coils is filled without interposing air to form the core. The coil apparatus characterized by the above-mentioned. In the coil device according to claim 1 or 2,
The magnetic device has a magnetic permeability of 15 to 70 H / m. The coil device according to any one of claims 1 to 3,
The coil device is characterized in that the housing is composed of at least one of a heat conductive resin and a metal. In the coil device according to any one of claims 1 to 4,
The plurality of coils are provided so as to be adjacent to each other in the radial direction,
A coil device, wherein a spacer made of a nonmagnetic material is interposed between the adjacent coils. In the coil device according to any one of claims 1 to 5,
The housing is formed with an opening,
The magnetic body contains a magnetic material and a resin material made of at least one of an epoxy resin and an unsaturated polyester resin, and a surface film is formed on the opening side surface of the housing of the magnetic body, The coil device, wherein the ratio of the resin material in the film is higher than that on the side opposite to the opening. The coil device according to any one of claims 1 to 6,
The area of the cross section passing through the axis of two coils of the plurality of coils of the magnetic body outside the coil in the axial direction is 0.6 to 1 of the area of the cross section perpendicular to the coil axis direction of the magnetic body inside the coil. Coil device characterized by being 5 times larger. In the coil device according to any one of claims 1 to 7,
The area of the cross section perpendicular to the coil axis direction of the magnetic body on the outer side in the circumferential direction of the coil is 0.2 to 1.5 times the area of the cross section perpendicular to the coil axis direction of the magnetic body on the inner side of the coil. Coil device characterized. A manufacturing method of a coil device including a plurality of coils, a housing that houses the plurality of coils, and a core that is inserted through each of the coils.
The plurality of coils are accommodated in the housing, and a liquid magnetic material containing a magnetic material and at least one of an epoxy resin and an unsaturated polyester resin is filled in the housing, and the magnetic material is cured in this state. Thus, a region that occupies at least a part of the entire inner circumferential surface in the axial direction of each coil and a majority in the circumferential direction of the outer circumferential surface is covered with the magnetic material made of the magnetic material without interposing air. A method for manufacturing a coil device.

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