JP2023048379A - Reactor - Google Patents

Abstract

To provide a reactor having a cooling unit for cooling a coil and a core, which can eliminate necessity of formation of a recess portion to be fitted by the coil by enhancing cooling performance.SOLUTION: A reactor 4 includes a cylindrical coil 7, a core 8 provided to penetrate the coil 7, a resin portion 9 that covers the coil 7 and the core 8, and a cooling unit 10 that cools the coil 7 and the core 8. The coil 7 has an exposed surface 7a that is a part of the peripheral surface of the coil 7 and is located outside the resin portion 9. The core 8 has a heat dissipation surface 8b1 which is located outside the resin portion 9 and arranged in the same plane as the exposed surface 7a. The cooling unit 10 is arranged in mechanical or thermal contact with the exposed surface 7a of the coil 7 and the heat dissipation surface 8b1 of the core 8.SELECTED DRAWING: Figure 2

Description

The present invention relates to reactors.

2. Description of the Related Art An electric vehicle such as an electric vehicle or a hybrid vehicle is equipped with a power conversion device that performs power conversion between a battery and a motor or the like. Such a power conversion device includes a capacitor and a reactor, converts DC power output from a battery into AC power, and feeds the motor with the AC power. Patent Literature 1 discloses a reactor provided in such a power converter.

A reactor disclosed in Patent Document 1 includes a resin portion that covers a coil and a core. A portion of the coil is exposed from the resin portion and placed on a metal case bottom plate that functions as a cooling portion.

WO2013/001591

In Japanese Unexamined Patent Application Publication No. 2002-100003, a recess is provided in the bottom plate of the metal case in order to improve heat dissipation, and part of the coil exposed from the resin portion is accommodated in this recess. By providing such a concave portion, the contact area between the coil and the metal case is increased, making it possible to improve the cooling efficiency of the coil and core.

However, in order to provide the cooling portion with the recess into which the coil is fitted, it is necessary to process the cooling portion to form the recess. As a result, the mold for forming the cooling part case becomes complicated, and the number of processing steps for the cooling part case increases.

The present invention has been made in view of the above-described problems, and aims to eliminate the need to form a recess in which the coil fits in the cooling part by improving the cooling performance in a reactor provided with a cooling part for cooling the coil and the core. With the goal.

The present invention employs the following configurations as means for solving the above problems.

A first aspect of the present invention includes a cylindrical coil, a core provided through the coil, a resin portion covering the coil and the core, and a cooling portion cooling the coil and the core. In the reactor, the coil has an exposed surface that is part of the peripheral surface of the coil and is positioned outside the resin portion, and the core is positioned outside the resin portion and has the exposed surface and the cooling part is arranged in contact with the exposed surface of the coil and the heat dissipation surface of the core.

According to a second aspect of the present invention, in the first aspect, the core has a main body part that penetrates the coil, and a heat radiation surface that protrudes radially outward from the main body part of the coil. A configuration is adopted in which an extension portion and a notch portion formed by notching a portion of the main body portion are provided.

According to a third aspect of the present invention, in the second aspect, a plurality of the coils are provided, and the main body portion of the core includes a plurality of penetrating portions provided for each of the coils and penetrating the coils. and a connecting portion connecting the through portions with each other and formed with the notch portion, and the extending portion is provided so as to protrude from the connecting portion.

According to a fourth aspect of the present invention, in any one of the first to third aspects, the cooling unit comprises: a heat radiating portion for radiating heat transferred from the coil and the core to the outside; A configuration is adopted in which an insulating heat-conducting member is interposed between the surface and the heat radiating portion.

According to a fifth aspect of the present invention, in the fourth aspect, the resin portion has a protruding wall portion that protrudes toward the cooling portion and abuts against the heat-conducting member in a direction orthogonal to the protruding direction. Adopt configuration.

According to a sixth aspect of the present invention, in the fifth aspect, the projecting wall portion is formed in a frame shape, and the heat conducting member is accommodated in a space surrounded by the projecting wall portion. Adopt configuration.

In the present invention, the core is provided with a heat dissipation surface arranged in the same plane as the exposed surface of the coil. The heat dissipation surface is arranged outside the resin portion and is in contact with the cooling portion in the same manner as the exposed surface of the coil. Therefore, according to the present invention, heat can be transferred not only from the exposed surface of the coil but also from the heat radiation surface of the coil to the cooling portion. Therefore, according to the present invention, it is possible to improve the cooling performance of the coil and the core as compared with the case where only the exposed surface of the coil is in contact with the cooling portion. Therefore, according to the present invention, in a reactor provided with a cooling portion for cooling a coil and a core, formation of a concave portion into which the coil is fitted in the cooling portion becomes unnecessary by enhancing the cooling performance.

BRIEF DESCRIPTION OF THE DRAWINGS It is an exploded perspective view which shows schematic structure of the power converter device provided with the reactor in 1st Embodiment of this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is a typical general view of the reactor in 1st Embodiment of this invention, (a) is a side view, (b) is a top view. BRIEF DESCRIPTION OF THE DRAWINGS It is a typical general view of the core with which the reactor in 1st Embodiment of this invention is provided, (a) is a top view, (b) is a side view, (c) is a front view. FIG. 5 is a schematic side view of a reactor according to a second embodiment of the invention; It is a typical general view of the resin part with which the reactor in 2nd Embodiment of this invention is provided, (a) is a side view, (b) is a bottom view. FIG. 5 is a schematic side view of a core included in a modification of the reactor according to the first embodiment of the invention;

An embodiment of a reactor according to the present invention will be described below with reference to the drawings.

(First embodiment)
FIG. 1 is an exploded perspective view showing a schematic configuration of a power conversion device 1 including a reactor 4 of this embodiment. The power conversion device 1 is mounted on a vehicle such as an electric vehicle, and is provided between a motor (load) (not shown) and a battery. Such a power conversion device 1 includes an intelligent power module 2, a capacitor 3, a reactor 4, a DCDC converter 5, and a body case 6, as shown in FIG.

The intelligent power module 2 includes a power module 20, a gate driver board 21, an ECU board 22, and the like. The power module 20 includes a plurality of power devices 20a having power semiconductor elements, a resin power module case 20b housing the power devices 20a, and a bus bar 20c connected to the power devices 20a. In addition, the power module 20 includes an insulating resin member that prevents a short circuit of the bus bar 20c, a water jacket for cooling, and the like.

The gate driver substrate 21 is a substrate provided with a gate driver for generating drive signals for the step-up/step-down converter and inverter formed by the power device 20a. Such a gate driver substrate 21 is laminated on the power module 20 . The ECU board 22 is a board provided with an ECU (Electronic Control Unit) for controlling the gate driver board 21 . The ECU board 22 is laminated on the gate driver board 21 .

The capacitor 3 is connected to the intelligent power module 2 and arranged on the side of the power module 20 . The reactor 4 of this embodiment is arranged below the intelligent power module 2 . The configuration of the reactor 4 of this embodiment will be described later in detail. The DCDC converter 5 is arranged on the side of the reactor 4 and below the intelligent power module 2 . Note that the DCDC converter 5 converts the battery power into a voltage suitable for surrounding electronic components (such as electronic components mounted on the gate driver board 21 and the ECU board 22).

The body case 6 is a case that houses the intelligent power module 2, the capacitor 3, the reactor 4, and the DCDC converter 5, and includes an upper case 6a, a central case 6b, and a lower case 6c. These upper case 6a, middle case 6b and lower case 6c are connected to the power module 20, the gate driver board 21 and the ECU board 22 so as to be separable in the stacking direction. The upper case 6a covers the intelligent power module 2 from the side of the ECU board 22 and is fastened to the central case 6b. The central case 6 b surrounds the intelligent power module 2 , capacitor 3 , reactor 4 and DCDC converter 5 . The lower case 6c covers the reactor 4 and the DCDC converter 5 from below, is provided with a connector for connecting the intelligent power module 2 and a motor (not shown), and is fastened to the central case 6b.

FIG. 2 is a schematic overall view of the reactor 4 of this embodiment, where (a) is a side view and (b) is a plan view. As shown in these figures, reactor 4 includes coil 7 , core 8 , resin portion 9 , and cooling portion 10 .

The coil 7 is formed in a cylindrical shape by winding a wire. In this embodiment, the two coils 7 are horizontally arranged so that their axial directions are parallel to each other. Each coil 7 is formed to have a substantially rectangular outer shape when viewed from the axial direction. For this reason, the circumferential surface of the coil 7 is provided with four planes.

A part of the coil 7 is exposed from the resin portion 9 . This exposed area includes one of four planes. That is, one of the four planes provided on the peripheral surface of the coil 7 is positioned outside the resin portion 9 . A plane positioned outside the resin portion 9 is referred to as an exposed surface 7a. Thus, in this embodiment, the coil 7 has an exposed surface 7 a that is part of the peripheral surface of the coil 7 and positioned outside the resin portion 9 .

FIG. 3 is a schematic overall view of the core 8, where (a) is a plan view, (b) is a side view, and (c) is a front view. The core 8 is a core material made of a conductive metal, is inserted into the tubular coil 7 , and is provided so as to penetrate the coil 7 . As shown in FIG. 3, the core 8 includes a body portion 8a, an extension portion 8b, and a notch portion 8c.

The body portion 8a is a portion through which the coil 7 is passed. The body portion 8a is entirely covered with a resin portion 9 and has two through portions 8a1 and two connection portions 8a2. The through portion 8 a 1 is provided for each coil 7 . Since two coils 7 are provided in this embodiment, two through portions 8a1 are also provided. Each penetrating portion 8a1 is formed in a rod shape penetrating through the central opening of the cylindrical coil 7. As shown in FIG.

The connection portion 8a2 is a portion that connects the through portions 8a1. One connecting portion 8a2 connects one end of one penetrating portion 8a1 and one end of the other penetrating portion 8a1. The other connecting portion 8a2 connects the other end of the through portion 8a1 and the other end of the through portion 8a1.

The extending portion 8b is a portion provided for each connection portion 8a2, and is provided so as to protrude from each connection portion 8a2. That is, two extending portions 8b are provided in this embodiment. Each extending portion 8b protrudes from each connecting portion 8a2 in the radial direction of the coil 7, and the tip thereof is located outside the resin portion 9. As shown in FIG. A heat dissipation surface 8b1 is provided at the tip of each extension 8b.

Each heat radiation surface 8b1 is arranged on the same plane as the exposed surface 7a of the coil 7. As shown in FIG. That is, the heat radiation surface 8b1 is included on a virtual plane including the exposed surface 7a. It should be noted that the fact that the heat dissipation surface 8b1 and the exposed surface 7a are provided on the same plane does not mean that the heat dissipation surface 8b1 and the exposed surface 7a are completely included in the same plane. , and allow deviations caused by mechanical errors and the like.

Thus, in the present embodiment, the core 8 has the heat dissipation surface 8b1 positioned outside the resin portion 9 and arranged in the same plane as the exposed surface 7a of the coil 7. As shown in FIG. The heat radiation surface 8b1 is in mechanical or thermal contact with the cooling portion 10 together with the exposed surface 7a.

The core 8 is divided into a part formed by one half of the body portion 8a and one extension portion 8b and a part formed by the other half of the body portion 8a and the other extension portion 8b. It is considered divisible. These parts are connected inside each coil 7 as shown in FIG.

The notch portion 8c is a portion formed by notching a part of the body portion 8a. The cutout portion 8c is a portion that reduces the volume of the core 8 that is increased by forming the extension portion 8b. As the volume of the core 8 is reduced by the notch portion 8c, the weight of the core 8 without the extending portion 8b approaches or becomes the same. Therefore, the inductance (weight specification) can be made the same as when the extension 8b is not provided.

In the present embodiment, the notch 8c is provided at the upper portion of the end of the connecting portion 8a2 opposite to the through portion 8a1. By providing the notch portion 8c at such a position, it is possible to ensure a large width of the connection portion 8a2 in the direction along the extending direction of the through portion 8a1. Therefore, it is possible to widen the installation space of the extending portion 8b, and it is possible to widen the heat radiation surface 8b1.

The resin portion 9 is a member that covers the coil 7 and the core 8, and is made of resin. That is, the coil 7 and core 8 are molded with the resin portion 9 . In this embodiment, a gap is provided between the resin portion 9 and the cooling portion 10 . A part of the coil 7 and a part of the extending portion 8b of the core 8 are arranged in this gap.

The cooling unit 10 cools the coil 7 and the core 8 by receiving heat from the coil 7 and the core 8 . In this embodiment, the cooling unit 10 includes a cooler 10a (radiator) and an insulating thermally conductive member 10b (thermally conductive member).

The cooler 10a is a water cooling jacket that performs cooling using, for example, coolant water as a coolant. Further, the cooler 10a may be a heat sink having a radiator plate. Such a cooler 10a radiates heat received from the coil 7 and the core 8 to the outside.

The insulating heat-conducting member 10b is a single sheet-like or gel-like member sandwiched between the coil 7 and the cooler 10a and between the core 8 and the cooler 10a. . That is, in this embodiment, the insulating heat-conducting member 10b is interposed between the coil 7/core 8 and the cooler 10a. The insulating heat-conducting member 10b is made of a material that is insulating and heat-conducting. It is possible to insulate the coil 7 and the core 8 from the cooler 10a by means of the insulating heat-conducting member 10b.

In the reactor 4 of this embodiment configured as described above, the temperature of the coil 7 and the core 8 rises due to the current flowing through the coil 7 . The heat of the coil 7 is transmitted from the exposed surface 7a to the cooling section 10 and released to the outside. Moreover, the heat of the core 8 is transmitted to the cooling portion 10 from the heat radiation surface 8b1 of the extending portion 8b and released to the outside. By transferring heat to the cooling part 10 in this way, the coil 7 and the core 8 are cooled.

The reactor 4 of this embodiment as described above includes the coil 7 , the core 8 , the resin portion 9 , and the cooling portion 10 . The coil 7 is formed in a cylindrical shape. The core 8 is provided so as to penetrate the coil 7 . The resin part 9 is provided so as to cover the coil 7 and the core 8 . The cooling part 10 cools the coil 7 and the core 8 . Further, in the reactor 4 of the present embodiment, the coil 7 has an exposed surface 7 a that is part of the peripheral surface of the coil 7 and positioned outside the resin portion 9 . Further, the core 8 has a heat dissipation surface 8b1 located outside the resin portion 9 and arranged in the same plane as the exposed surface 7a. Further, the cooling part 10 is arranged in mechanical or thermal contact with the exposed surface 7a of the coil 7 and the heat radiation surface 8b1 of the core 8 .

In the reactor 4 of the present embodiment as described above, the core 8 is provided with the heat radiation surface 8 b 1 arranged on the same plane as the exposed surface 7 a of the coil 7 . The heat radiation surface 8b1 is arranged outside the resin portion 9 and is in mechanical or thermal contact with the cooling portion 10 in the same manner as the exposed surface 7a of the coil 7. As shown in FIG. Therefore, according to the reactor 4 of the present embodiment, heat can be transferred not only from the exposed surface 7a of the coil 7 but also from the heat radiation surface 8b1 of the coil 7 to the cooling portion 10 .

Therefore, according to the reactor 4 of the present embodiment, the cooling performance of the coil 7 and the core 8 can be improved more than when only the exposed surface 7a of the coil 7 is in mechanical or thermal contact with the cooling section 10. It becomes possible. Therefore, according to the reactor 4 of the present embodiment, in the reactor 4 including the cooling unit 10 that cools the coil 7 and the core 8, by enhancing the cooling performance, it is unnecessary to form a recess in which the coil 7 is fitted in the cooling unit 10. Become.

Moreover, in the reactor 4 of the present embodiment, the core 8 has a main body portion 8a, an extension portion 8b, and a notch portion 8c. The main body portion 8 a penetrates the coil 7 . The extending portion 8b protrudes radially outward of the coil 7 from the body portion 8a and has a heat radiation surface 8b1. The notch portion 8c is formed by notching a portion of the body portion 8a.

According to the reactor 4 of this embodiment, the volume of the core 8, which is increased by forming the extending portion 8b, can be reduced by the notch portion 8c. Since the volume of the core 8 is reduced by the notch 8c, the weight of the core 8 without the extension 8b becomes close to or equal to the weight of the core 8. It can be the same as when it is not provided.

Further, by providing the cutout portion 8c at the upper portion of the end of the connection portion 8a2 opposite to the through portion 8a1, a large width of the connection portion 8a2 in the extending direction of the through portion 8a1 can be secured. Therefore, it is possible to widen the installation space of the extending portion 8b, and it is possible to widen the heat radiation surface 8b1.

Moreover, the reactor 4 of this embodiment includes a plurality of coils 7 . Further, the body portion 8a of the core 8 includes a through portion 8a1 and a connection portion 8a2. The penetrating portion 8 a 1 is provided for each coil 7 and penetrates the coil 7 . The connecting portion 8a2 connects the through portions 8a1 and has a notch portion 8c. Further, an extension portion 8b is provided so as to protrude from the connection portion 8a2.

According to the reactor 4 of the present embodiment, the extending portion 8b extends from the connecting portion 8a2 positioned outside the coil 7 . Therefore, it is possible to secure a large installation area for the extension portion 8b. Therefore, by widening the heat dissipation surface 8b1, it is possible to improve the heat dissipation effect.

In addition, in the reactor 4 of the present embodiment, the cooling section 10 has a cooler 10a and an insulating heat-conducting member 10b. The cooler 10a radiates heat transferred from the coil 7 and the core 8 to the outside. The insulating heat-conducting member 10b is interposed between the exposed surface 7a and the heat radiation surface 8b1 and the cooler 10a. According to the reactor 4 of this embodiment, the coil 7 and the core 8 can be insulated from the cooler 10a.

(Second embodiment)
Next, a second embodiment of the invention will be described with reference to FIGS. 4 and 5. FIG. In the description of the present embodiment, the description of the same parts as those of the first embodiment will be omitted or simplified.

FIG. 4 is a schematic side view of the reactor 4A of this embodiment. As shown in this figure, in the reactor 4A of the present embodiment, the resin portion 9 has a surrounding wall 9a (protruding wall portion). FIG. 5 is a schematic overall view of the resin portion 9, where (a) is a side view and (b) is a bottom view. The surrounding wall 9a is provided in the lower part of the resin part 9, and is formed in a frame shape so as to form an accommodation space S inside. The lower end of the surrounding wall 9a is in contact with the cooler 10a of the cooling section 10. As shown in FIG.

In this embodiment, the insulating heat-conducting member 10b is accommodated in the accommodation space S formed by the surrounding wall 9a of the resin portion 9. As shown in FIG. The surrounding wall 9a is in contact with the insulating heat-conducting member 10b housed in the housing space S from the side (in a direction orthogonal to the downward direction, which is the projecting direction of the surrounding wall 9a). Such a surrounding wall 9a prevents the insulating heat-conducting member 10b from moving with respect to the cooler 10a.

Therefore, in this embodiment, it is not necessary to firmly fix the insulating heat-conducting member 10b to the cooler 10a. Therefore, for example, a configuration in which no adhesive is interposed between the cooler 10a and the insulating heat-conducting member 10b or a configuration in which the amount of adhesive to be used is reduced can be adopted. Therefore, it becomes possible to increase the heat conductivity of the cooler 10a from the insulating heat-conducting member 10b and further improve the cooling efficiency.

Further, in the present embodiment, the surrounding wall 9a is formed in a frame shape and is in contact with the insulating heat-conducting member 10b from the front, rear, left and right. Therefore, it is possible to prevent the insulating heat-conducting member 10b from moving with respect to the cooler 10a in any of the front, rear, left, and right directions.

However, it is not always necessary to provide the frame-shaped surrounding wall 9a. If a protruding wall portion is provided that abuts on the side portion of the insulating heat-conducting member 10b from one of the left, right, front and back directions or from a plurality of directions, the insulating heat transfer member 10b may be provided. It is possible to prevent the transmission member 10b from moving with respect to the cooler 10a.

Although the preferred embodiments of the present invention have been described above with reference to the accompanying drawings, it goes without saying that the present invention is not limited to the above embodiments. The various shapes, combinations, and the like of the constituent members shown in the above-described embodiment are merely examples, and can be variously changed based on design requirements and the like without departing from the gist of the present invention.

For example, in the above embodiment, the configuration in which two coils 7 are provided has been described. However, the invention is not limited to this. The number of coils 7 can be changed. In such a case, for example, the core 8 may also be configured to have through portions 8a1 corresponding to the number of coils 7. As shown in FIG.

Moreover, in the above-described embodiment, the configuration in which the core 8 has the notch portion 8c has been described. However, the invention is not limited to this. FIG. 6 is a schematic diagram showing the shape of the core without the notch 8c. As shown in this figure, it is also possible to employ a configuration in which the core does not have the notch 8c.

In such a case, the length of the penetrating portion 8a1 is increased to reduce the weight increased by the extending portion 8b in order to make the weight characteristics similar to those of the core in which the extending portion 8b is not provided. can be shortened.

1 power converter, 2 intelligent power module, 3 capacitor, 4 reactor, 4A reactor, 5 DCDC converter, 6 body case, 7 coil, 7a exposure Surface 8... Core 8a... Main body portion 8a1... Penetration part 8a2... Connection part 8b... Extension part 8b1... Heat dissipation surface 8c... Notch part 9... Resin part, 9a...surrounding wall, 10...cooling section, 10a...cooler (heat dissipation section), 10b...insulating thermally conductive member (thermally conductive member), S...accommodating space

Claims (6)

A reactor comprising a cylindrical coil, a core penetrating the coil, a resin part covering the coil and the core, and a cooling part cooling the coil and the core,
the coil has an exposed surface that is part of the peripheral surface of the coil and is located outside the resin portion;
the core includes a heat dissipation surface located outside the resin portion and arranged in the same plane as the exposed surface;
The reactor, wherein the cooling part is arranged in contact with the exposed surface of the coil and the heat radiation surface of the core. The core is
a main body penetrating through the coil;
an extending portion projecting from the body portion toward the outside in the radial direction of the coil and having the heat dissipation surface;
The reactor according to claim 1, further comprising a notch portion formed by notching a portion of the body portion. comprising a plurality of said coils,
The main body of the core comprises:
a plurality of penetrating portions provided for each of the coils and penetrating the coils;
a connecting portion connecting the through portions and having the notch formed thereon;
The reactor according to claim 2, wherein the extending portion is provided so as to protrude from the connecting portion. The cooling unit is
a heat radiating part that radiates heat transferred from the coil and the core to the outside;
4. The reactor according to any one of claims 1 to 3, further comprising an insulating heat-conducting member interposed between the exposed surface and the heat radiation surface and the heat radiation portion. 5. The reactor according to claim 4, wherein the resin portion has a protruding wall portion that protrudes toward the cooling portion and abuts against the heat conducting member in a direction orthogonal to the protruding direction. 6. The reactor according to claim 5, wherein the projecting wall portion is formed in a frame shape, and the heat conducting member is accommodated in a space surrounded by the projecting wall portion.

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