JP4514031B2 - Coil component and coil component manufacturing method - Google Patents

Description

  The present invention relates to a coil component and a manufacturing method thereof, and more particularly, to a coil component used as a reactor in energy control of a storage battery mounted in an electric vehicle or a hybrid car and a manufacturing method thereof.

  The driving frequency of coil parts used for boosting and regenerating in electric vehicles and hybrid cars ranges from several kHz to several tens of kHz in the audible range, so during driving, between the coil wires and between the coil and the magnetic core. There is a problem that audible noise and beat are generated due to vibrations caused by the mutual attractive force. In addition, there has been no magnetic core configuration that does not cause magnetic saturation even when a large current of 200 A or more flows, for example, without providing an air gap. In addition to the possibility, vibration may occur between the cores with the gap therebetween.

  A coil component having a magnetic core made of resin and magnetic powder is known (see Patent Document 1). The coil component of Patent Document 1 includes a powder magnetic core made of a ferrite sintered body or metal magnetic powder in addition to a magnetic core made of resin and magnetic powder. The coil is wound around the dust core, and a magnetic core made of resin and magnetic powder is provided so as to cover the coil.

JP 2001-185421 A

  One of the objects of Patent Document 1 is to provide a magnetic element such as an inductor, a choke coil, or a transformer that can reduce noise generation during driving.

  However, as will be described below, it is considered that the noise regarded as a problem in Patent Document 1 is caused by a mechanism different from at least the audible noise and the beat which is regarded as a problem in the present application.

  As is clear from the description in the column 0006 of Patent Document 1, the frequency range targeted by the coil component described in Patent Document 1 is a so-called “high frequency”, which is a frequency region far exceeding the audible frequency. Actually, there is a description of “several hundred kHz to MHz” in the column 0006 of Patent Document 1, and the term “high frequency” is frequently used as a keyword.

  Even if the air gap part vibrates at a very high frequency of several hundred kHz to MHz, it will only generate sound that cannot be heard by the human ear, and it is possible that it will result in audible noise and beating as described above. Absent.

  Therefore, it is appropriate to consider a solution for audible noise and beat caused by driving in the audible frequency band, apart from the technique described in Patent Document 1.

  In addition, the coil component that is the target in Patent Document 1 is a coil component for a low-power system, as is clear from the size illustrated. Therefore, as a matter of course, withstand voltage performance of several hundred volts or more and unwanted pulse current performance of several hundred amperes or more (resistance against unwanted current noise such as surge current) cannot be expected.

  As described above, it is appropriate to consider that it is inappropriate to use the coil component described in Patent Document 1 for high power / low frequency applications.

  In view of the above, the present invention has a coil component that has high withstand voltage performance and high anti-unnecessary pulse current performance, and can suppress audible noise and beat even when driven at a frequency that is in the audible frequency range. It aims at providing the manufacturing method.

  According to the present invention, at least a part of the coil inclusion insulating enclosure obtained by surrounding the coil with the insulator made of at least the first resin so as to remove the end of the coil, at least the magnetic powder is contained. A coil component characterized by being embedded in a magnetic core made of a composite of a powder containing and a second resin is obtained.

  In the coil component described above, since the coil is surrounded by an insulator made of at least the first resin, it has excellent withstand voltage characteristics and unnecessary pulse current performance, and includes at least a magnetic powder. Since the movement of the coil is fixed because it is embedded in the magnetic core made of a mixture of powder and the second resin, even if it is driven in the audible frequency band, audible noise and beat are generated. Vibration does not occur.

  Hereinafter, the coil component according to the first embodiment of the present invention will be described in detail with reference to FIGS.

  The coil component 100 according to the first embodiment has a structure in which a coil inclusion insulating enclosure 60 as shown in FIGS. 4 to 6 is completely embedded in a magnetic core 80.

  The coil inclusion insulating enclosure 60 has a structure obtained by surrounding the coil 30 with the insulator 50 made of the first resin. However, the end portions 12 and 22 of the coil 30 are not surrounded by the insulator 50.

  As shown in FIGS. 1 and 2, the coil 30 according to the present embodiment has a glasses-like structure formed by connecting coil portions 10 and 20 obtained by vertically winding a flat conducting wire. Specifically, the coil portion 10 includes end portions 12 and 14, and similarly, the coil portion 20 includes end portions 22 and 24. The end portion 14 of the coil portion 10 is connected to the end portion 24 of the coil portion 20. Thus, when a current is passed from the end 12 of the coil unit 10 to the end 22 of the coil unit 20, a magnetic flux flowing in the opposite direction is generated in the coil unit 10 and the coil unit 20. The magnetic flux flows in the opposite directions are combined with each other to form a single magnetic path loop. In other words, the coil portions 10 and 20 are connected to the end portions 14 and 24 so as to be magnetically connected in series. In the present embodiment, as shown in the figure, a configuration in which two coil parts 10 and 20 that are individual parts are physically connected is adopted, but the coil part 10 is formed by vertically winding a flat wire. Thereafter, a continuous coil 30 may be constituted by a single rectangular conductive wire by further winding the rectangular conductive wire vertically so as to continuously form the coil 20 as it is.

  FIG. 3 shows a process of forming the coil inclusion insulating enclosure 60 according to the present embodiment using the coil 30 obtained as described above. Referring to FIG. 3, it is understood that the shape of the temporary casting container 40 is first selected according to the shape of the coil inclusion insulating enclosure 60 to be created. The temporary casting container 40 includes two internal cylindrical protrusions 42 and an outer portion 44 having a cross-sectional shape 8. Although not shown in the drawing, the two inner cylindrical protrusions 42 and the outer section 44 having a cross section 8 are connected to each other at the bottom of the temporary casting container 40 having an 8-shaped plane. ing.

  A first insulator spacer 46 is disposed at the bottom of the temporary casting container 40. The first insulator spacer 46 is made of the same material as the insulator 50 described later, and the thickness of each of the first insulator spacers 46 is an insulator in the axial direction of the coil 30 in the coil inclusion insulation envelope 60 to be produced. Is substantially equal to a thickness of 50 (shown as t2 in FIG. 6).

  After the first insulator spacer 46 is disposed at the bottom of the temporary casting container 40, the coil 30 is placed thereon. At this time, the coil 30 is positioned at a position away from the bottom of the temporary casting container 40 by t2. However, since only the position in the axial direction of the coil 30 (that is, the vertical direction of the coil inclusion insulating enclosure 60) is positioned by the first insulator spacer 46, the radial direction of the coil 30 (that is, the coil inclusion). In order to position the insulating enclosure 60 in the horizontal direction), the second insulator spacer 48 is inserted around the coil 30 in the radial direction. The thickness of the second insulator spacer 48 is substantially equal to the thickness of the insulator 50 in the radial direction of the coil 30 in the coil inclusion insulating enclosure 60 (shown as t1 in FIGS. 5 and 6).

  When the first and second insulator spacers 46 and 48 are appropriately positioned in the vertical and horizontal directions in the casting container 40 between the coil 30 and the casting container 40 as described above. The material of the insulator 50 is filled so as to satisfy the above.

  In the present embodiment, the insulator 50 is made of an epoxy resin. Hereinafter, the resin constituting the insulator 50 is referred to as a first resin.

  Since the epoxy resin, which is the first resin, is required to be liquid and have low viscosity, compatibility with additives, curing agents, catalysts, and storage stability are important factors to be considered in selecting specific epoxy resins. It is a characteristic. In consideration of such circumstances, epoxy resins such as bisphenol A type, bisphenol F type, and polyfunctional type can be used as the main agent, and aromatic polyamine type, carboxylic acid anhydride type, latent curing agent as the curing agent. A system type can be used. In this example, a combination of a bisphenol A type epoxy resin and a solvent-free low viscosity liquid aromatic amine curing agent was used.

  The first resin may be another thermosetting resin such as a silicone resin, or may be cured without applying heat such as a chemically reactive curable resin, an ultraviolet curable resin, or a photocurable resin. A curable resin may be used.

  In any case, the filled first insulating resin is cured so that the space between the coil 30 and the casting container 40 is filled, and thus the coil-containing insulating enclosure as shown in FIGS. A product 60 is obtained.

  As is apparent from FIGS. 4 to 6, the coil inclusion insulating enclosure 60 according to the present embodiment thus obtained has hollow portions 62 and 64 corresponding to the two hollow portions 32 and 34 of the coil 30. have. In addition, as a dimension of the insulator 50 between the two coil portions, it has a thickness t3 in the Y direction (a direction perpendicular to the direction in which the coil portions are arranged) and a thickness t4 in the X direction (the direction in which the coil portions are arranged). Have.

  The coil inclusion insulating enclosure 60 thus obtained is positioned and arranged in the case 70 as shown in FIG.

  The positioning material is a spacer made of the same material as the magnetic core 80. Since the magnetic core 80 in the present embodiment is formed from a hybrid of resin and magnetic powder as described later, this spacer is called a hybrid spacer. In addition, resin which comprises a hybrid is called 2nd resin, in order to distinguish with resin (1st resin) which comprises the insulator 50. FIG. However, although the two are distinguished as the first and second resins in terms of names, in the present embodiment, both are made of the same resin material. The reason why the first resin and the second resin are made of the same resin is to make the coil inclusion insulating enclosure 60 properly and easily integrated when the coil inclusion insulating enclosure 60 is embedded in the magnetic core 80. is there.

  Referring to FIG. 7, first, the first hybrid spacer 72 is appropriately disposed on the bottom surface of the case 70, and the coil inclusion insulating enclosure 60 is placed thereon. Thereby, positioning in the vertical direction of the coil inclusion insulating enclosure 60 is made. Next, the second and third hybrid spacers 74 and 76 are arranged around the coil inclusion insulating enclosure 60 in the horizontal direction, whereby the coil inclusion insulation enclosure 60 is also positioned in the horizontal direction. The sizes of the first, second, and third hybrid spacers 72, 74, and 76 can be appropriately changed depending on where the coil inclusion insulating enclosure 60 is to be arranged in the case 70. . In the present embodiment, as shown in FIGS. 8 to 10, the coil inclusion insulating enclosure 60 is formed in the magnetic core 80 made of a hybrid in the case 70 except for the end portions 12 and 22 of the coil 30. The first, second and third hybrid spacers 72, 74 and 76 are sized so that they are completely buried.

  After the coil inclusion insulating enclosure 60 is positioned in the case 70 using the first to third hybrid spacers 72, 74, and 76 as described above, as shown in FIGS. The mixture of the second resin 82 and the magnetic powder 84 is poured into the case 70 so that the space between the case 70 and the coil inclusion insulating enclosure 60 is filled, and the second resin 82 is cured. A magnetic core 80 according to the present embodiment is obtained.

  As is clear from the above description, the magnetic core 80 made of a hybrid is a cast product formed by casting the hybrid. Here, when the size is large as in the case of a coil component for high power use, particularly when considering the case where the coil component has a certain height or more, the composite material may be made of a material that can be cast without adding a solvent. preferable.

  Casting is basically performed without pressure or under reduced pressure. Once the casting is performed, pressure may be applied to improve the filling rate (density of the magnetic core 80). There is no restriction | limiting in particular about the type | mold shape at the time of casting a hybrid material, Therefore All shapes can be considered as a shape of the magnetic core 80 which consists of a hybrid material.

  The magnetic powder 84 constituting the hybrid is a soft magnetic powder, specifically, an Fe-based soft magnetic metal powder. More specifically, the soft magnetic metal powder is a powder selected from the group consisting of Fe-Si powder, Fe-Si-Al powder, Fe-Ni powder, and Fe amorphous powder. Here, the average Si content in the Fe—Si based powder is preferably 0.0 wt% or more and 11.0 wt% or less. Further, the average Si content in the Fe—Si—Al-based powder is preferably 0.0 wt% or more and 11.0 wt% or less, and the average Al content is preferably 0.0 wt% or more and 7.0 wt%. It is as follows. Further, the average Ni content in the Fe—Ni-based powder is preferably 30.0 wt% or more and 85.0 wt% or less.

  In particular, a substantially spherical powder is used as the magnetic powder 84 according to the present embodiment. Thus, when the substantially spherical magnetic powder 84 is used, the filling rate of the magnetic powder 84 in the hybrid can be improved. The substantially spherical magnetic powder 84 is obtained by, for example, a gas atomization method. According to the gas atomization method, the particle size and shape of the magnetic powder 84 have a certain degree of distribution. As a guide, the most standard particle size (average particle size) of the magnetic powder 84 is 500 μm or less. It is desirable that if it exceeds this, sufficient yield, characteristics and performance cannot be obtained.

  According to the gas atomization method, a non-spherical powder can be intentionally formed in addition to the substantially spherical powder as described above. Moreover, according to the water atomization method, an amorphous powder can also be obtained. In the present invention, non-spherical powder, amorphous powder, and other shapes of powder obtained by the above method can be used instead of the substantially spherical powder employed in the embodiment. The reason why the magnetic powder 84 other than the substantially spherical shape is adopted is to use anisotropy due to its shape, for example. More specifically, for example, a non-spherical, flat, or needle-shaped magnetic powder 84 is mixed with the second resin 82, and a predetermined magnetic field is applied before the resin 82 is cured. A method of using isotropic orientation and then curing the resin 82 can be considered.

  The blending ratio of the second resin 82 in the hybrid product needs to be 20% by volume or more and 90% by volume or less in consideration of fluidity and the like. Preferably, the blending ratio of the second resin 82 in the hybrid is 40% by volume or more and 70% by volume or less.

  In consideration of low noise use for reducing audible range noise and beat, the elastic modulus of the magnetic core 80 made of a composite needs to be 3000 MPa or more. In this case, in order to achieve the elastic modulus of the magnetic core 80, the second resin 82 cures the second resin 82 alone under the same conditions as those for obtaining the magnetic core 80 by curing the composite. In this case, the elastic modulus of the resin 82 is selected so as to be 100 MPa or more. Note that the elastic modulus of the magnetic core 80 or the cured resin 82 is a value measured according to JIS-K6911 (thermosetting plastic general test method).

  In the present embodiment, the elastic modulus of the magnetic core 80 made of a hybrid is 15000 MPa, and the elastic modulus of the second resin 82 alone cured under the same curing conditions is 1500 MPa. When the elastic modulus of the magnetic core 80 is 15000 MPa or more, the thermal conductivity is improved to 2 W / (K · m) or more compared to the case where the thermal conductivity is less than that. Therefore, the elastic modulus of the magnetic core 80 is preferably 15000 MPa or more.

FIG. 19 shows the direct current superposition characteristics of the magnetic core 80 obtained from a hybrid obtained by mixing 50% by volume of Fe—Si based powder and epoxy resin. As is clear from FIG. 19, the relative permeability of the magnetic core 80 made of the hybrid in the present embodiment does not suddenly saturate even in a magnetic field of 1000 × 10 ³ / 4π [A / m]. It has a relatively high relative permeability of 15 or more.

The above-described magnetic core 80 can be appropriately changed as long as the relative permeability is 10 or more in a magnetic field of 1000 × 10 ³ / 4π [A / m]. For example, in order to slightly increase the initial permeability, a high permeability thin film layer may be formed on the surface of the magnetic powder 84. Here, an example of the high magnetic permeability thin film is an Fe—Ni thin film. In order to avoid an electrical short circuit due to the magnetic powder 84, the magnetic powder 84 may be coated with one or more insulating layers before being mixed with the resin. Here, when a high permeability thin film is formed on the surface of the magnetic powder 84, an insulating layer is coated on the formed high permeability thin film. Furthermore, a nonmagnetic filler may be added to the composite of the magnetic powder 84 and the second resin 82 in order to ensure a high relative permeability in a higher magnetic field. Examples of the nonmagnetic filler include a group consisting of silica powder, alumina powder, titanium oxide powder, quartz glass powder, zirconium powder, calcium carbonate powder or aluminum hydroxide powder, glass fiber, and granular resin. One filler selected from Instead of the nonmagnetic filler, a hollow glass sphere may be mixed with the resin for adjusting the magnetic permeability. Further, in order to extend the direct current superposition characteristics well into a higher magnetic field, a small amount of permanent magnet powder may be added to apply a magnetic bias to the magnetic core 80.

  In the present embodiment, as described above, the first resin that forms the insulator 50 of the coil inclusion insulating enclosure 60 and the second resin 82 that is the material of the composite of the magnetic core 80 are cured in the same manner. As a functional resin, a new noise prevention is made by physically matching the two so that stress that may occur when driven in a low frequency region does not divide the two. As another method for achieving physical matching between the two, adding a nonmagnetic filler to the insulator 50 can be mentioned.

  The nonmagnetic filler added to the insulator 50 is obtained when at least one of the elastic modulus or the linear expansion coefficient exhibited by the magnetic core 80 and the insulator 50 are cured when the hybrid is cured to form the magnetic core 80. Are selected so as to correspond to the elastic modulus or the linear expansion coefficient exhibited by. As the nonmagnetic filler in this case, a nonmagnetic filler that can be added to the above-mentioned hybrid can be used. That is, examples of nonmagnetic fillers that can be added to the insulator 50 include silica powder, alumina powder, titanium oxide powder, quartz glass powder, zirconium powder, calcium carbonate powder or aluminum hydroxide powder, glass fiber, And one filler selected from the group consisting of granular resins. Needless to say, the first and second resins may be made of the same curable resin, and further, a nonmagnetic filler may be added to the insulator 50 to aim at the above effect. .

  The nonmagnetic filler added to the insulator 50 is preferably a substantially spherical powder, and the average particle size is desirably 500 μm or less.

  The mixing ratio of the first resin and the nonmagnetic filler in the insulator 50 is required to be 30% by volume or more in consideration of fluidity. In addition, when using the magnetic resistance height of the insulator 50 when compared with the magnetic core 80 as described later, the content of the nonmagnetic filler is preferably 50% by volume or more. That is, in this case, the blending ratio of the first resin is 30% by volume or more and 50% by volume or less.

  Here, the dimensional relationship between the thicknesses t1, t2, and t4 (see FIGS. 5 and 6) of each part of the insulator 50 and the particle diameter d1 of the magnetic powder 84 constituting the magnetic core 80 will be described. In order to ensure good insulating properties, the thicknesses t1, t2, and t4 of the insulator 50 are desirably larger than one third of the particle diameter d1 of the magnetic powder 84. That is, t1> d1 / 3, t2> d1 / 3, and t4> d1 / 3. Similarly, when the particle size of the nonmagnetic filler added to the insulator 50 is d2, the thicknesses t1, t2, and t4 of the insulator 50 are larger than one third of the particle size d2 of the nonmagnetic filler. Is desirable. That is, t1> d2 / 3, t2> d2 / 3, and t4> d2 / 3. Furthermore, in order to avoid a short path mode of magnetic flux that is not effective in the magnetic circuit, it is desirable that t3 ≧ t4> d2 / 3.

  Case 70 in the present embodiment is made of an aluminum alloy. The case 70 may be formed of other metal / alloy such as Fe—Ni alloy. When the case is made of metal, in order to ensure appropriate insulation performance, it is preferable to form an insulating film on the inner surface of the case 70 and then cast the composite to form the magnetic core 80. The case 70 may be a ceramic case such as an alumina molded body.

  In the present embodiment, the magnetic core 80 and the coil inclusion insulating enclosure 60 embedded in the case 70 are fixed to the case 70 by casting a hybrid to the case 70. The present invention is not limited to this. For example, once a temporary case is created with a combination of fluororesin sheets, and a composite is cast on the temporary case, thereby forming a coil component including the magnetic core 80 and the coil inclusion insulating enclosure 60. good. This is because, for example, the case 70 that functions as a magnetic yoke is used as a common part with other parts, so that the coil part is temporarily formed without the case 70, and then the coil part is disposed in the case 70 as the common part. It is effective in the case.

  Next, a coil component according to a second embodiment of the present invention will be described with reference to FIGS. In the coil component according to the second embodiment, since only the shape of the coil inclusion insulating enclosure 61 is different from the coil component 100 according to the first embodiment, the following description will focus on this. .

  As is apparent from a comparison of FIGS. 13 and 5, the Y-direction thickness t5 in the region between the coil portions of the coil inclusion insulating enclosure 61 according to this embodiment is equal to the coil inclusion insulation enclosure 60 according to the first embodiment. This is much larger than the thickness t3 in the Y direction in the inter-coil region. Since the thickness t5 is a result of increasing the amount of the insulator 50 in the coil inclusion insulating enclosure 61, it has the same effect as arranging a high magnetoresistive region 54 between the coil portions.

  More specifically, as shown in FIGS. 14 and 15, the high magnetic resistance extending in parallel with the axial direction of the coil 30 between the two coil portions of the coil inclusion insulating enclosure 60 according to the first embodiment. The areas 56 and 58 are added in the Y direction. The high magnetoresistance region 54 (56, 58) is formed of the same material as that of the insulator 50, and has a relative magnetic permeability of 20 or less in the present embodiment. Due to the presence of the high magnetic resistance region 54 (56, 58), the magnetic flux generated in each of the two coil portions constituting the coil 30 efficiently passes through the hollow portions of the other coil portions.

  In the present embodiment, the high magnetoresistance region 54 as described above can be formed only by selecting the shape of the temporary casting container 41. That is, as apparent from a comparison between FIG. 3 and FIG. 11, the outer portion 45 has a cross-sectional shape that is closer to the track for athletics than the figure of 8. Thereby, the coil inclusion insulating enclosure 62 having the high magnetoresistance region 54 as shown in FIGS. 12 and 13 can be easily formed. Theoretically, first, the coil inclusion insulating enclosure 60 according to the first embodiment is formed, and then a separately prepared high magnetoresistance member (having a shape like the high magnetoresistance regions 56 and 58) is prepared. Although it is possible to adhere to this, it goes without saying that the manufacturing method introduced in this embodiment is more advantageous in that it can suppress an increase in cost.

  Next, a coil component according to a third embodiment of the present invention will be described with reference to FIGS. The coil component 110 according to the third embodiment has a high magnetic property made of a material having a higher magnetic resistance than a hybrid material that is a material of the magnetic core 80 in a part of the magnetic path in the coil component 100 according to the first embodiment. The resistance member 90 is arranged.

  When such a high magnetic resistance member 90 is inserted into a part of the magnetic path, there is an advantage that the inductance of the coil component is less likely to be saturated even in a high magnetic field.

  The high magnetoresistance member 90 in the present embodiment is made of the same material as the insulator 50, and forms a high magnetoresistance region having a relative permeability of 20 or more in the magnetic path. The high magnetic resistance member 90 may be formed of, for example, the same resin as the first resin included in the insulator 50, or may be formed by mixing the same resin with a nonmagnetic filler different from the insulator 50. Also good. In addition, the high magnetic resistance member 90 is, for example, a predetermined amount with respect to the same resin as the first resin included in the insulator 50 (the amount that results in the magnetic resistance of the high magnetic resistance member 90 being higher than that of the hybrid). ) Magnetic material powder may be mixed.

  As shown in FIG. 18, the high magnetic resistance member 90 is disposed in the hollow portion of the coil 30. This is because magnetic flux leakage does not occur from the portion of the high magnetic resistance member 90 if the high magnetic resistance member 90 is in this position. As can be understood from FIG. 18, in the present embodiment, two high magnetoresistance members 90 are arranged in parallel to each other in the hollow portions of the coil portions constituting the coil 30. In order to arrange each high magnetoresistive member 90 at such a position, for example, when the hybrid material reaches an appropriate level in the middle of casting the hybrid material into the case 70, it is prepared in advance. What is necessary is just to drop and arrange | position the high magnetoresistive member 90 in the predetermined position of the hollow part of a coil inclusion insulating enclosure.

  As shown in FIGS. 16 and 17, each high magnetic resistance member 90 has a concave lens shape having a concave surface 92 and a flat surface 94. In this manner, the illustrated coil component 110 is configured such that the magnetic flux generated in each coil portion efficiently passes through the central region of the other coil portion.

  The shape of the high magnetoresistive member 90 is not limited to that shown in FIGS. 16 and 17, and if the thickness of the central portion is smaller than the thickness of the outer peripheral portion, the distribution of the magnetic flux density is also the same. Averaging can be achieved. When a flat plate shape (with opposed parallel planes) is adopted as the shape of the high magnetoresistive member 90, the average density distribution of the magnetic flux is slightly inferior, but the first embodiment Thus, there is an advantage that the inductance is less likely to be saturated as compared with the case where the high magnetic resistance member 90 is not provided.

  Various modifications can be made to the embodiment described above under the concept of the present invention. For example, in the first to third embodiments described above, the coil inclusion insulating enclosures 60 and 61 are provided with the insulator 30 made of the first resin or the first resin and a nonmagnetic filler. However, as long as the insulation characteristics of the coil 30 (insulation between lines and insulation between coils) can be ensured, other forms may be adopted.

  For example, as shown in FIG. 20, a coil-containing insulating enclosure 160 having an insulator 150 may be used. The insulator 150 has a substantially cylindrical profile having a hollow portion 151, and includes a bobbin 152 and a cover 156. The material of the bobbin 152 and the cover 156 is the same as the first resin in the first to third embodiments described above. A helical groove 153 is formed in the bobbin 152. The coil 30 is wound around the bobbin 152 so as to be held in the groove 153, and as a result, the coil 30 is disposed in a space formed by the groove 153 and the cylindrical cover 156. As shown in FIG. 20, the spiral groove 153 has a wall (insulating portion between wires) 154 made of an insulating material between the groove portions, as shown in FIG. 20. Adjacent parts are appropriately insulated from each other.

  As shown in FIGS. 21 and 22, a part of the magnetic path of the coil component 200 may be configured by a specific permeability magnetic core member 210 made of a conventional dust core or laminated magnetic core.

  In this case, the specific permeability magnetic core member 210 is disposed around the coil inclusion insulating enclosure 260 and / or in the hollow portion 261, and the specific permeability magnetic core member 210 is formed by the magnetic core 80 made of a hybrid. It is fixed to the coil inclusion insulating enclosure 260.

  Examples of the specific magnetic permeability core member 210 include a powder magnetic core member made of Fe-based amorphous powder, or Fe-Si-Al-based, Fe-Si-based, or Fe-Ni-based powder, or an Fe-based laminated magnet. A core member is mentioned.

  The coil 30 in the first to third embodiments is obtained by vertically winding a flat wire. For example, as shown in FIG. 22, a coil 30 or a litz wire wound by a round wire is used. It may be formed by winding. Further, although the coil 30 in the first to third embodiments is a glasses-like shape composed of two coil portions, it may be a solenoid coil as shown in FIG. 22 or a toroidal. A coil may be used.

  Furthermore, in the above-described embodiment, the coil inclusion insulating enclosures 60 and 61 and the coil components 100 and 110 are positioned while the coil 30 is positioned using the insulator spacers 46 and 48 and the hybrid spacers 72, 74 and 76. The case where the coil 30 is formed has been described. For example, when the member itself of the coil 30 has a certain degree of rigidity, the insulation is performed in a state where the end portions 12 and 22 of the coil 30 are held and the coil 30 is suspended. If the body 50 or the magnetic core 80 is cast, the same configuration can be manufactured. Similar coil components 100 and 110 can also be formed by casting the insulator 50 or the magnetic core 80 in a state where the coil 30 is suspended by a fluororesin wire or the like.

  As examples of application destinations of the magnetic core and the coil parts that have been described with specific examples above, for example, a coil part for control of voltage increase or a coil part for control of voltage drop used in solar power generation or wind power generation, etc. There is.

It is a perspective view which shows the coil part contained in the coil components by the 1st Embodiment of this invention. It is a perspective view which shows the coil formed from the coil part shown by FIG. It is a perspective view which shows the manufacturing process of the coil inclusion insulation enclosure contained in the coil components by 1st Embodiment. It is a perspective view which shows the coil inclusion insulation enclosure manufactured according to the manufacturing process shown by FIG. It is a top view of the coil inclusion insulation enclosure shown by FIG. It is sectional drawing of the coil inclusion insulation enclosure shown by FIG. It is a perspective view which shows the manufacturing process of the coil components by 1st Embodiment. It is a perspective view which shows the coil components by 1st Embodiment. FIG. 9 is a top view of the coil component shown in FIG. 8. FIG. 10 is a cross-sectional view of the coil component shown in FIG. 9. It is a perspective view which shows the manufacturing process of the coil inclusion insulation enclosure contained in the coil components by the 2nd Embodiment of this invention. It is a perspective view which shows the coil inclusion insulation enclosure manufactured according to the manufacturing process shown by FIG. It is a top view of the coil inclusion insulation enclosure shown by FIG. It is a perspective view used in order to demonstrate the structure of the coil inclusion insulation enclosure shown by FIG. It is a top view used in order to demonstrate the structure of the coil inclusion insulation enclosure shown by FIG. It is a perspective view which shows the high magnetoresistive member contained in the coil components by the 3rd Embodiment of this invention. It is sectional drawing of the high magnetoresistive member shown by FIG. It is sectional drawing which shows the coil components by 3rd Embodiment containing the high magnetoresistive member shown by FIG.16 and FIG.17. It is a graph which shows the direct current superimposition characteristic of the magnetic core used for the coil components in embodiment of this invention. It is a figure which shows the modification of a coil inclusion insulation enclosure. Here, the coil inclusion insulating enclosure includes a bobbin and a cover. It is a perspective view which shows the other modification of a coil component. It is sectional drawing of the coil components shown by FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Coil part 12 End part 14 End part 20 Coil part 22 End part 24 End part 30 Coil 32 Hollow part 34 Hollow part 40 Temporary casting container 41 Temporary casting container 42 Cylindrical internal protrusion part 44 Outside Part 45 Outer part 46 First insulating material spacer 48 Second insulating material spacer 50 Insulator 52 Insulator 54 High magnetic resistance region 56 High magnetic resistance region 58 High magnetic resistance region 60 Coil inclusion insulating enclosure 61 Coil inclusion insulation enclosure Material 62 Hollow portion 64 Hollow portion 70 Case 72 First hybrid spacer 74 Second hybrid spacer 76 Third hybrid spacer 80 Magnetic core 82 Second resin 84 Magnetic powder 90 High magnetic resistance member 92 Concave surface 94 Plane 100 Coil part 110 Coil part 150 Insulator 151 Hollow part 152 Bobbin 153 Groove 154 Line insulation part 156 Cover 200 Coil component 210 Specific magnetic permeability core member 260 Coil inclusion insulation

Claims (48)

A coil component used as a reactor in energy control of a storage battery mounted in an electric vehicle or a hybrid car,
At least part of the coil-containing insulating enclosure obtained by surrounding the coil with the insulator made of the first resin so as to remove the end of the coil, at least part of the powder containing magnetic powder and the second resin Embedded in a magnetic core made of a hybrid material with
The coil encapsulated insulation enclosure is Ri castings der obtained the insulator by casting,
The blending ratio of the second resin is 20% by volume or more and 90% by volume or less,
The coil component according to claim 1, wherein the elastic modulus of the magnetic core made of the hybrid is 3000 MPa or more .   2. The coil component according to claim 1, wherein the coil inclusion insulating enclosure is completely embedded in a magnetic core made of the composite except for an end portion of the coil.   The coil component according to claim 1 or 2, wherein the first resin and the second resin are made of the same curable resin.   4. The coil component according to claim 1, wherein each of the first resin and the second resin is a thermosetting resin. 5.   The coil component according to any one of claims 1 to 4, wherein a thin film layer having a high magnetic permeability is formed on a surface of the magnetic substance powder.   The coil component according to claim 1, wherein the magnetic powder is coated with one or more insulating layers before being mixed with the second resin. The second mixing ratio of the resin is 70 vol% or less than 40 vol%, a coil component according to claim 1 to 6, wherein the in the hybrids. The coil component according to any one of claims 1 to 7 , wherein the second resin in the hybrid is an epoxy resin or a silicone resin. The coil component according to any one of claims 1 to 8 wherein the insulator first resin is an epoxy resin or a silicone resin, characterized by. The coil component according to any one of claims 1 to 9, wherein the magnetic powder is made of a soft magnetic powder, characterized in that. The coil component according to claim 10, wherein the soft magnetic powder is a soft magnetic metal powder. The coil component according to claim 11, wherein the soft magnetic metal powder is Fe—Si based powder. The coil component according to claim 12, wherein the average Si content in the Fe-Si powder is 0.0 wt% or more and 11.0 wt% or less. The coil component according to claim 11, wherein the soft magnetic metal powder is Fe-Si-Al-based powder. The average Si content in the Fe-Si-Al-based powder is 0.0 wt% or more and 11.0 wt% or less, and the average Al content is 0.0 wt% or more and 7.0 wt% or less. The coil component according to claim 14 . The coil component according to claim 11, wherein the soft magnetic metal powder is Fe—Ni-based powder. The coil component according to claim 16, wherein an average Ni content in the Fe-Ni-based powder is 30.0 wt% or more and 85.0 wt% or less. The coil component according to claim 11, wherein the soft magnetic metal powder is an Fe-based amorphous powder. The magnetic powder is substantially spherical powder, a coil component according to any of claims 1 to 18, characterized in that. In the case where the thickness of the insulator in the radial direction of the coil is the first thickness and the thickness of the insulator in the axial direction of the coil is the second thickness, both the first and second thicknesses The coil component according to any one of claims 1 to 19 , wherein the coil component is larger than one third of an average particle diameter of the magnetic powder. The coil component according to any one of claims 1 to 20 , wherein the hybrid material includes a nonmagnetic filler. The magnetic core made of the hybrid has a relative magnetic permeability of 10 or more in a magnetic field of 1000 × 10 ³ / 4π [A / m], according to any one of claims 1 to 21 . Coil parts. The coil component according to any one of claims 1 to 22 , wherein the insulator is formed by adding a nonmagnetic filler to the first resin. The nonmagnetic filler associates at least one of an elastic modulus or a linear expansion coefficient exhibited when the hybrid is cured with an elastic modulus or a linear expansion coefficient exhibited when the insulator containing the nonmagnetic filler is cured. 24. The coil component according to claim 23 , wherein the coil component is selected as described above. The nonmagnetic filler is selected from the group consisting of silica powder, alumina powder, titanium oxide powder, quartz glass powder, zirconium powder, calcium carbonate powder or aluminum hydroxide powder, glass fiber, and granular resin. The coil component according to claim 23 or 24 , wherein the coil component is a single filler. 26. The coil component according to claim 23 , wherein the nonmagnetic filler is a substantially spherical powder. In the case where the thickness of the insulator in the radial direction of the coil is the first thickness and the thickness of the insulator in the axial direction of the coil is the second thickness, both the first and second thicknesses 27. The coil component according to claim 26 , wherein the coil component is larger than one third of an average particle diameter of the magnetic powder and larger than one third of an average particle diameter of the nonmagnetic filler. The coil according to any one of claims 23 to 27 , wherein a blending ratio of the first resin in the insulator made of the first resin and the nonmagnetic filler is 30% by volume or more. parts. The coil component according to any one of claims 1 to 28 , wherein the coil inclusion insulating enclosure has a hollow portion surrounded by the coil. It further includes at least one specific permeability magnetic core member arranged around the coil inclusion insulating enclosure and / or in the hollow portion, and the specific permeability magnetic core member is formed by the magnetic core made of the hybrid. 30. The coil component according to claim 29 , wherein the coil component is fixed to the coil inclusion insulating enclosure. The specific permeability magnetic core member is a powder magnetic core member made of Fe-based amorphous powder, Fe-Si-Al-based, Fe-Si-based, or Fe-Ni-based powder, or an Fe-based laminate. The coil component according to claim 30 , wherein the coil component is a magnetic core member. 32. The coil component according to claim 29 , further comprising a high magnetic material member embedded in the magnetic core made of the hybrid and having a higher magnetic resistance than the hybrid. The coil component according to claim 32, wherein the high magnetic material member is made of a material containing the same resin as the first resin. 34. The coil component according to claim 33, wherein the high magnetic material member is made of the same material as the insulator. 35. The coil component according to claim 29, wherein the high magnetic material member is disposed in the hollow portion. 36. The coil component according to claim 35, wherein there are at least two high magnetic material members, and the high magnetic material members are arranged so as to be parallel to each other. 37. The coil component according to claim 35 or 36, wherein the high magnetic material member has a shape in which the thickness of the central portion is thinner than the thickness of the outer peripheral portion. The coil component according to any one of claims 32 to 37 , wherein the high magnetic material member forms a region having a relative permeability of 20 or less inside the magnetic core made of the hybrid. 30. The coil component according to claim 29 , wherein the magnetic core made of the hybrid constitutes a loop of a magnetic path passing through a hollow portion of the coil. The coil has a shape obtained by connecting two or more coil portions so that the axial directions of the respective coil portions are parallel to each other and two adjacent coil portions form one magnetic path. has a any of claims 1 to 39 wherein the adjacent two of said coil portions high magnetic resistance region which extends in the direction parallel to the axial direction of the coil portion is formed, it is characterized by The coil component according to crab. 41. The coil component according to claim 40, wherein the high magnetoresistance region has a relative magnetic permeability of 20 or less. The coil component according to claim 40 or 41, wherein the high magnetic resistance region is made of a material containing the same resin as the first resin. 43. The coil component according to claim 42, wherein the high magnetoresistance region is made of the same material as the insulator. A coil inner insulating enclosure is disposed in the case, and the magnetic core made of the hybrid material fills a space between the coil inner insulating enclosure and the case, and the coil inner insulating enclosure. The coil component according to any one of claims 1 to 43 , wherein an object is enclosed in the magnetic core. 45. The coil component according to claim 44, wherein the case is a ceramic case or a metal case having an inner surface formed with an insulating layer. 46. The coil component according to claim 45, wherein the metal case is made of aluminum or an Fe-Ni alloy, or the ceramic case is made of an alumina molded body. The coil component according to any one of claims 1 to 46 , wherein the magnetic core is a cast product obtained by casting the composite. 48. The coil component according to claim 47 , wherein the composite is made of a material that can be cast without using a solvent.

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