JP4867889B2 - Power converter and manufacturing method thereof - Google Patents

Description

  The present invention relates to a power conversion device incorporating a reactor and a method for manufacturing the same.

2. Description of the Related Art Conventionally, for example, there is a power conversion device such as an inverter that is used to generate a drive current for energizing an AC motor that is a power source of an electric vehicle or a hybrid vehicle.
In the power conversion device, a semiconductor module that forms part of the power conversion circuit, a cooler that cools the semiconductor module, a reactor that forms part of the boost circuit for boosting the input voltage, and the like. It is stored in the case.

  And as said reactor, what has a coil which generates a magnetic flux by electricity supply, and a core which consists of magnetic powder mixed resin with which the inner side and outer periphery of this coil were filled may be used. For example, as disclosed in Patent Document 1, such a reactor is solidified by placing a coil in a case, pouring a liquid magnetic powder mixed resin into the case, and then heating the magnetic powder mixed resin. It is formed by making a core.

Therefore, when forming the reactor in the case of the power converter, in order to solidify the magnetic powder mixed resin, it is necessary to put the case of the power converter into the curing furnace and to heat the case. And since the case of this power converter device accommodates components other than a reactor including the said semiconductor module and a cooler, its volume is large and its heat capacity is also large.
As a result, the curing furnace is increased in size, the required heating energy is increased, and the heating time is increased.

JP 54-13994 A

  The present invention has been made in view of such conventional problems, and an object of the present invention is to provide a power conversion device and a method for manufacturing the same that can reduce the size of manufacturing equipment and reduce the manufacturing cost.

A first invention is a method of manufacturing a power conversion device including a reactor having a coil that generates magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil,
In providing the reactor in the case of the power converter,
After the coil and the magnetic powder mixed resin are arranged in a molding die different from the case , the magnetic powder mixed resin is thermoset to mold the reactor,
After thermally expanding the reactor accommodating portion provided in the case, the reactor taken out from the mold is disposed in the accommodating portion, and then the accommodating portion is cooled and contracted, The power conversion device manufacturing method includes performing a shrink fitting process of fixing the reactor to the housing portion (claim 1).

Next, the effects of the present invention will be described.
In the method for manufacturing the power converter, the reactor is disposed in the case of the power converter by performing the molding step and the shrink fitting step. That is, first, in the molding step, the reactor is molded with a molding die different from the case. Therefore, when the magnetic powder mixed resin is solidified to form a core, only the reactor portion may be charged into a curing furnace or the like and heated. Therefore, it is not necessary to put the entire case of the power conversion device into the curing furnace or to heat it.

  As a result, it is possible to reduce the size of manufacturing equipment such as a curing furnace, to reduce the heating energy, and to shorten the heat curing time. In other words, the reactor can be obtained by the minimum manufacturing equipment size, heat energy, and heating time substantially necessary for forming the reactor.

  Moreover, in the said manufacturing method, since a reactor is fixed to the accommodating part of a case according to the said shrink fitting process, a reactor can be fixed in a case easily and reliably.

  As described above, according to the first aspect of the present invention, it is possible to provide a method for manufacturing a power converter capable of reducing the size of manufacturing equipment and reducing the manufacturing cost.

According to a second aspect of the present invention, there is provided a reactor having a coil that generates a magnetic flux when energized, a core made of a magnetic powder mixed resin filled inside and around the coil, a semiconductor module containing a semiconductor element, and the semiconductor module. A method of manufacturing a power converter having a cooler for cooling,
The cooler is formed by arranging a plurality of cooling pipes and connecting the cooling pipes at both ends by connecting pipes.
In providing the reactor in the case of the power converter,
A molding step of molding the reactor using a molding die different from the case;
The reactor is between the plurality of the connecting pipe, the method of manufacturing a power converter which is characterized in that the clamping step of clamping during the cooling tube of the upper Kifuku number (claim 5).

Next, the effects of the present invention will be described.
In the method for manufacturing the power converter, the reactor is disposed in the case of the power converter by performing the molding step and the clamping step. That is, similarly to the first invention, first, in the molding step, the reactor is molded by a molding die different from the case. Therefore, it is possible to reduce the size of manufacturing equipment such as a curing furnace for curing the magnetic powder mixed resin that constitutes the core of the reactor, and also to reduce heating energy, which in turn shortens the heat curing time. Can also be planned.

  Moreover, in the said manufacturing method, since a reactor is clamped between several cooling pipes by the said clamping process, a reactor can be fixed in a case easily and reliably. In addition, the cooling efficiency of the reactor can be improved.

  As described above, according to the second aspect of the invention, it is possible to provide a method for manufacturing a power conversion device that can reduce the size of manufacturing equipment and reduce the manufacturing cost.

A third invention is a method of manufacturing a power conversion device including a reactor having a coil that generates magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil,
In providing the reactor in the case of the power converter,
A molding step of molding the reactor using a molding die different from the case;
A fixing step of fixing the reactor to the reactor housing provided in the case;
There lines and a resin filling step of filling the resin into the gap between the inner surface and the reactor of the accommodating portion,
In the molding step, the reactor is molded while inserting a holed member provided with a bolt insertion hole inside the coil, and in the fixing step, a bolt inserted into the bolt insertion hole of the holed member is used. The reactor is fastened to the housing portion . The method of manufacturing a power conversion device according to claim 7.

Next, the effects of the present invention will be described.
In the method for manufacturing the power conversion device, the reactor is disposed in the case of the power conversion device by performing the molding step, the fixing step, and the resin filling step. That is, similarly to the first invention, first, in the molding step, the reactor is molded by a molding die different from the case. Therefore, it is possible to reduce the size of manufacturing equipment such as a curing furnace for curing the magnetic powder mixed resin that constitutes the core of the reactor, and also to reduce heating energy, which in turn shortens the heat curing time. Can also be planned.

Moreover, in the said manufacturing method, since a reactor is fixed to a case by the said fixing process, a reactor can be fixed easily and reliably in a case.
Furthermore, in the said manufacturing method, resin is filled into the clearance gap between the inner surface of the said accommodating part and the said reactor in the said resin filling process. Therefore, heat transfer from the reactor to the case can be improved, and the cooling efficiency of the reactor can also be improved.

Further, by interposing the resin between the case and the reactor, it is possible to absorb the vibration of the reactor and suppress the vibration from being transmitted to the case.
In addition, since there is the resin filling step, it is possible to ensure a sufficient clearance between the housing accommodating portion of the case and the reactor, and to easily arrange the reactor in the accommodating portion.

  As described above, according to the third aspect of the invention, it is possible to provide a method for manufacturing a power conversion device that can reduce the size of manufacturing equipment and reduce manufacturing costs.

A fourth invention is a power conversion device incorporating a reactor having a coil that generates a magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil,
The reactor is fixed to the reactor accommodating portion provided in the case by shrink fitting, and is pressed against the accommodating portion from the outer periphery to be tightened. Claim 9 ).

Next, the effects of the present invention will be described.
In the power converter, the reactor is fixed in the case of the power converter by shrink fitting. Therefore, a reactor molded in advance separately from the case can be fixed to the housing portion of the case. Therefore, when the magnetic powder mixed resin constituting the reactor is solidified to form a core, only the reactor portion may be charged into a curing furnace or the like and heated. Therefore, when manufacturing a power converter, it is not necessary to put the entire case of the power converter into a curing furnace or to heat it.

As a result, it is possible to reduce the size of manufacturing equipment such as a curing furnace, to reduce the heating energy, and to shorten the heat curing time.
Moreover, since the reactor is fixed to the housing portion of the case by shrink fitting, the reactor can be easily and reliably fixed in the case.

  As described above, according to the fourth aspect of the invention, it is possible to provide a power conversion device that can reduce the size of manufacturing equipment and reduce manufacturing costs.

According to a fifth aspect of the present invention, there is provided a reactor having a coil that generates a magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and around the coil, a semiconductor module containing a semiconductor element, and the semiconductor module. A power converter having a cooler for cooling,
The cooler is formed by arranging a plurality of cooling pipes and connecting the cooling pipes at both ends by connecting pipes.
The reactor is in a power converter characterized by being sandwiched between the plurality of cooling pipes among the plurality of connecting pipes ( claim 13 ).

Next, the effects of the present invention will be described.
In the power converter, the reactor is fixed in the case of the power converter by sandwiching the reactor between the plurality of cooling pipes. Therefore, similarly to the fourth aspect of the invention, it is possible to fix a reactor molded in advance separately from the case in the case. Therefore, it is possible to reduce the size of manufacturing equipment such as a curing furnace for curing the magnetic powder mixed resin that constitutes the core of the reactor, and also to reduce heating energy, which in turn shortens the heat curing time. Can also be planned.

  Further, since the reactor is sandwiched between the plurality of cooling pipes, the reactor can be easily and reliably fixed in the case. In addition, the cooling efficiency of the reactor can be improved.

  As described above, according to the fifth aspect of the invention, it is possible to provide a power converter that can reduce the size of manufacturing equipment and reduce manufacturing costs.

A sixth invention is a power conversion device incorporating a reactor having a coil that generates a magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil,
The reactor is fixed to the reactor accommodating portion provided in the case,
The gap between the inner surface of the housing part and the reactor is filled with a resin different from the core ,
The reactor is molded in a state where a holed member provided with a bolt insertion hole is inserted inside the coil, and is fastened to the housing portion by a bolt inserted into the bolt insertion hole of the holed member. It is in the power converter device characterized by the above-mentioned ( Claim 15 ).

Next, the function and effect of this example will be described.
In the power conversion device, the reactor is fixed to the accommodating portion provided in the case, and a gap between the inner surface of the accommodating portion and the reactor is filled with a resin different from the core, A reactor is disposed in the case of the power converter. Therefore, similarly to the fourth aspect of the invention, it is possible to fix a reactor molded in advance separately from the case in the case. Therefore, it is possible to reduce the size of manufacturing equipment such as a curing furnace for curing the magnetic powder mixed resin that constitutes the core of the reactor, and also to reduce heating energy, which in turn shortens the heat curing time. Can also be planned.

In addition, since the resin is filled in the gap between the inner surface of the housing part and the reactor, the heat transfer rate from the reactor to the case can be improved, and the cooling efficiency of the reactor can be improved. .
Further, by interposing the resin between the case and the reactor, it is possible to absorb the vibration of the reactor and suppress the vibration from being transmitted to the case.

  As described above, according to the sixth aspect of the invention, it is possible to provide a power conversion device that can reduce the size of manufacturing equipment and reduce manufacturing costs.

A seventh invention is a reactor in which a coil that generates a magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and around the coil are accommodated in a reactor case,
In the gap between the inner surface of the reactor case and the core, a damping material having thermal conductivity is disposed, and the reactor case and the core are not in direct contact ,
In the core inside the coil, a core disposed so as to penetrate in the axial direction of the coil is embedded in contact with the core, and between the core and the reactor case. Is provided in the reactor characterized in that the damping material is interposed ( claim 17 ).

Next, the effects of the present invention will be described.
In the reactor, the reactor case and the core are not in direct contact. Therefore, the vibration transmission path from the core to the reactor case can be reduced, and the vibration of the core can be prevented from being transmitted to the outside of the reactor through the reactor case.
Moreover, the said damping material which has thermal conductivity is arrange | positioned in the clearance gap between the inner surface of the said reactor case, and the said core. Therefore, the heat of the core can be transmitted to the reactor case, and the heat dissipation of the reactor can be sufficiently secured. Moreover, the vibration transmission to the reactor case can be suppressed by absorbing the vibration of the core by the damping material.

  As described above, according to the seventh aspect of the invention, it is possible to provide a reactor that can suppress the transmission of vibration and is excellent in heat dissipation.

An eighth invention is a power conversion device equipped with the reactor according to the seventh invention, wherein the reactor case is a part of the case of the power conversion device. ( Claim 25 ).
In the said power converter device, while being able to suppress transmission of the vibration of a reactor, the heat dissipation of a reactor can be improved.
Therefore, according to the eighth aspect of the present invention, it is possible to provide a power conversion device that can suppress transmission of vibration and is excellent in heat dissipation.

In the first to eighth inventions, the magnetic powder mixed resin is a material obtained by mixing magnetic powder into a resin. Examples of the magnetic powder include ferrite powder, iron powder, and silicon alloy iron powder. Moreover, as said resin, thermosetting resins, such as an epoxy resin, and a thermoplastic resin can be used, for example.
Moreover, it is preferable that the said case consists of a metal excellent in heat conductivity, such as aluminum or aluminum alloy, for example.

In the first invention (invention 1), it is preferable that the reactor has a substantially cylindrical shape, and the accommodating portion has a substantially cylindrical shape along the shape of the reactor (invention 2).
In this case, the reactor can be tightened substantially uniformly from the outer periphery by the housing portion. Therefore, the reactor can be stably fixed in the case.

In addition, it is preferable that convex or concave positioning means that engage with each other are provided on the outer peripheral surface of the reactor and the inner side surface of the housing portion.
In this case, it is possible to prevent the reactor from being displaced in the housing portion. Therefore, it is possible to prevent the reactor from being displaced even when an external force such as vibration is applied to the power converter.

Moreover, it is preferable that the said accommodating part is comprised by the frame which has substantially constant thickness (Claim 4).
In this case, when the housing portion shrinks in the shrink fitting process, it is possible to prevent the shrinkage dimension from being varied depending on the frame portion of the housing portion. Thereby, the frame of the accommodating part can fasten the reactor from the outer periphery with a substantially uniform pressing force, and can stably fix the reactor.

Next, in the second invention (invention 5), the reactor is formed by integrally forming a metal member exposed on a surface not in contact with the cooling pipe, and a part of the metal member is brought into contact with the cooling pipe. (Claim 6).
In this case, the cooling efficiency of the reactor can be improved. That is, if there is no metal member, it is difficult to radiate the reactor from the surface direction that does not come into contact with the cooling pipe that sandwiches the reactor. Therefore, by integrally forming a metal member on this surface and bringing the metal member into contact with the cooling pipe, the heat of the reactor can be radiated to the cooling pipe through the metal member.

Next, in the third invention, in the molding step, the reactor is molded while inserting a holed member provided with a bolt insertion hole, and in the fixing step, the bolt insertion hole of the holed member. by inserting the bolts that enter into the reactor in the accommodating portion.
Thereby , the said reactor can be fixed to the accommodating part of the said case easily and reliably. Moreover, if the said member with a hole is comprised by the member excellent in thermal conductivity, such as aluminum, for example, the heat of a reactor can be radiated | emitted to a case via this member with a hole, and the reactor excellent in heat dissipation efficiency can be provided. Obtainable.

In the above fixing step, after placing the reactor into the accommodating portion, but it may also be pressed against the reactor to the receiving portion by a spring.
Also in this case, the reactor can be easily and reliably fixed to the housing part of the case.

Further, on the outer peripheral surface of the reactor, it is preferable to continuously form the groove in the axial direction (claim 8).
In this case, in the resin filling step, the resin can be filled smoothly between the inner side surface of the housing portion and the reactor. That is, in injecting the resin into the gap between the inner surface of the housing portion and the reactor, the resin can smoothly penetrate to the bottom of the housing portion through the resin flow space between the groove portion and the inner surface of the housing portion. it can. Thereby, resin can be smoothly circulated and filled in the whole clearance gap between a reactor and the inner surface of a accommodating part. As a result, it is possible to prevent air from entering between the reactor and the housing portion, to ensure good heat transfer between the reactor and the case, and to improve the cooling efficiency.

In the fourth aspect of the present invention (invention 9 ), the reactor preferably has a substantially cylindrical shape, and the accommodating portion preferably has a substantially cylindrical shape along the shape of the reactor (invention 10 ).
In this case, the reactor can be tightened substantially uniformly from the outer periphery by the housing portion, and the reactor can be stably fixed in the case.

Further, the outer peripheral surface and an inner surface of the housing portion of the reactor is preferably formed by providing a convex or concave positioning means engage each other (claim 11).
In this case, it is possible to prevent the reactor from being displaced in the housing portion.

Moreover, it is preferable that the said accommodating part is comprised by the frame which has substantially constant thickness ( Claim 12 ).
In this case, when the reactor is shrink-fitted into the housing portion, the frame body of the housing portion can fasten the reactor from the outer periphery with a substantially uniform pressing force, and can stably fix the reactor.

Next, in the fifth invention (invention 13 ), the reactor is formed by integrally forming a metal member exposed on a surface that does not contact the cooling pipe, and a part of the metal member is in contact with the cooling pipe. ( Claim 14 ).
In this case, the heat of the reactor can be radiated to the cooling pipe through the metal member, and the cooling efficiency of the reactor can be improved.

Next, in the sixth invention, the reactor is molded in a state in which a holed member provided with a bolt insertion hole is inserted, and the bolt is inserted into the bolt insertion hole of the holed member. that is fastened to the housing portion.
Thereby , the said reactor can be fixed to the accommodating part of the said case easily and reliably. Moreover, if the said member with a hole is comprised by the member excellent in thermal conductivity, such as aluminum, for example, the heat of a reactor can be radiated | emitted to a case via this member with a hole, and the reactor excellent in heat dissipation efficiency can be provided. Obtainable.

In the above fixing step, the reactor, but it may also optionally be pressed against the housing part by a spring in a state of being arranged in the housing part.
Also in this case, the reactor can be easily and reliably fixed to the housing part of the case.

Moreover, it is preferable that the groove part is continuously formed in the axial direction in the outer peripheral surface of the said reactor ( Claim 16 ).
In this case, in the resin filling step, the resin can be filled smoothly between the inner side surface of the housing portion and the reactor. As a result, it is possible to prevent air from entering between the reactor and the housing portion, to ensure good heat transfer between the reactor and the case, and to improve the cooling efficiency.

Then, in the seventh invention, the damping material is preferably higher thermal conductivity than the core (Claim 18).
In this case, since the heat of the core can be efficiently transmitted to the reactor case via the damping material, the heat dissipation of the reactor can be further improved.

The vibration damping material is preferably made of a resin ( claim 19 ).
In this case, the vibration damping material can be easily disposed between the inner surface of the reactor case and the core.
Moreover, as said resin, a urethane, an epoxy, a silicon | silicone etc. can be used, for example. In addition, the vibration damping material may improve thermal conductivity by mixing a filler such as metal into the resin.

Furthermore, the damping material may be made of a lower metal plate hardness than the core (Claim 20).
In this case, for example, since the drying and curing steps required when the vibration damping material is made of resin are not required, the manufacturing process can be simplified and the cost can be reduced. As a result, an easily manufactured and inexpensive reactor can be obtained.
As the metal plate, for example, aluminum or the like can be used.

Furthermore, the damping material is preferably formed by embossing (claim 21).
In this case, the vibration of the core can be absorbed in the embossed portion, and the vibration transmission of the reactor can be further suppressed.

The core inside the coil is embedded with a core disposed so as to penetrate in the axial direction of the coil, and the damping material is interposed between the core and the reactor case. but that has been interposed.
Thereby , it can suppress that the vibration of a core transmits to a reactor case through the said center core.
Moreover, as the damping material, for example, a damping steel plate in which a resin is disposed between a pair of metal plates, a heat radiation sheet made of silicon or the like, a resin, or the like can be used.
In addition, for example, the core preferably has an insertion hole for inserting a fastening member such as a bolt, and by fastening the fastening member inserted through the insertion hole to the reactor case, the core is removed. The core can be fixed to the reactor case.

Also, the reactor casing preferably has a skin effect depth or thickness which is determined by the material of the drive frequency and the reactor casing of the reactor (claim 22).
In this case, the magnetic flux generated by the coil can be prevented from leaking out of the reactor case. Thereby, it can prevent affecting the electronic device arrange | positioned around a reactor.

Also, the reactor casing is preferably made of non-magnetic material (claim 23).
In this case, it is possible to prevent the magnetic circuit of the magnetic flux generated by the reactor from being affected and to form a desired magnetic circuit. As a result, the inductance of the reactor can be improved. That is, when the reactor case is made of a magnetic material, eddy currents may be generated due to magnetic flux passing through the case, which may affect the magnetic circuit. However, the reactor is made of a non-magnetic material. This can be prevented.
As the non-magnetic material, for example, aluminum can be used.

Also, the reactor casing is preferably formed so as to cover the entire surface of the core (Claim 24).
In this case, leakage of magnetic flux generated by the coil can be prevented in all directions.

Example 1
A power converter according to an embodiment of the present invention and a manufacturing method thereof will be described with reference to FIGS.
As shown in FIGS. 2 and 5, the power conversion device 1 of this example includes a coil 21 that generates magnetic flux when energized, and a core 22 that is formed of a magnetic powder mixed resin filled inside and outside the coil 21. 2 is built-in.

In providing the reactor 2 in the case 3 of the power converter 1, the following molding process and shrink-fitting process are performed.
In the molding step, as shown in FIG. 2, the reactor 2 is molded using a molding die 4 different from the case 3.
In the shrink fitting process, as shown in FIGS. 3 and 4, after the reactor accommodating portion 31 provided in the case 3 is thermally expanded, the reactor 2 is arranged in the accommodating portion 31 and then accommodated. The reactor 2 is fixed to the accommodating portion 31 by cooling and contracting the portion 31.

The case 3 of the power conversion device 1 is made of aluminum, and as shown in FIGS. 1 and 5, a reactor accommodating portion 31 is integrally formed on a part of the inside thereof. As shown in FIGS. 1 and 4, the accommodating portion 31 is provided inside a frame 310 made of aluminum having a rectangular parallelepiped shape.
Reactor 2 has a substantially cylindrical shape, and accommodating portion 31 has a substantially cylindrical shape along the shape of reactor 2.

In the reactor 2 molding step, first, as shown in FIG. 2A, the coil 21 is disposed at a predetermined position in the molding die 4, and then a liquid magnetic powder mixed resin 220 is injected into the molding die 4. The magnetic powder mixed resin 220 is a material obtained by mixing magnetic powder into a resin. Examples of the magnetic powder include ferrite powder, iron powder, and silicon alloy iron powder.
Further, as the resin, for example, a thermosetting resin such as an epoxy resin or a phenol resin can be used. For example, when a PPS resin, an unsaturated polyester resin, a nylon resin or the like is used, the magnetic powder is formed by injection molding. The mixed resin 220 can be formed into the core 22.

Further, the pair of terminals 211 of the coil 21 protrude from the core 22 made of the magnetic powder mixed resin 220.
Next, the coil 21 and the magnetic powder mixed resin 220 disposed in the mold 4 are put into the curing furnace together with the mold 4 and heated at a predetermined temperature for a predetermined time. Thereby, the magnetic powder mixed resin 220 is solidified to form the core 22 and the reactor 2 is molded.
Then, the reactor 2 molded and solidified in the mold 4 is taken out from the mold 4 as shown in FIG.

Further, when the reactor 2 taken out from the mold 4 is fixed in the housing portion 31 of the case 3, the following shrink fitting process is performed.
Note that at room temperature, the size of the accommodating portion 31 is formed to be slightly smaller than the size of the reactor 2 as shown in FIG. And first, the accommodating part 31 (frame 310) of case 3 is heated, and the accommodating part 31 is expanded so that it may become larger than the external shape of the reactor 2. FIG.

Next, as shown in FIGS. 3B and 4A, the reactor 2 molded in the molding process is placed in the expanded accommodating portion 31. At this time, the reactor 2 is kept at room temperature or in a cooled state.
Subsequently, the accommodating part 31 (frame 310) is cooled to normal temperature. Thereby, as shown in FIG. 3C and FIG. 4B, the accommodating portion 31 is contracted so that the reactor 2 is tightened from the outer periphery by the accommodating portion 31.
As described above, the reactor 2 is fixed to the accommodating portion 31 in the case 3.

  In addition to the reactor 2, various electronic components and the like are disposed in the case 3 of the power conversion device 1. In particular, as shown in FIG. 5, the main circuit portion 11 composed of a plurality of semiconductor modules constituting a part of the power conversion circuit and a cooler for cooling the semiconductor modules occupies most of the case 3. Further, the reactor 2 is electrically connected to the main circuit unit 11 and is electrically connected to an external power source. The reactor 2 constitutes a part of a boosting unit that boosts DC power supplied from a power source and sends the boosted DC power to the main circuit unit 11.

Next, the function and effect of this example will be described.
In the method for manufacturing the power converter, the reactor 2 is disposed in the case 3 of the power converter 1 by performing the molding step and the shrink fitting step. That is, first, the reactor 2 is molded by the molding die 4 different from the case 3 in the molding step. Therefore, when solidifying the magnetic powder mixed resin to form the core 22, only the reactor 2 portion may be charged into a curing furnace or the like and heated. Therefore, it is not necessary to put the entire case 3 of the power conversion device 1 into a curing furnace or to heat it.
As a result, it is possible to reduce the size of manufacturing equipment such as a curing furnace, to reduce the heating energy, and to shorten the heat curing time. That is, the reactor 2 can be obtained by the minimum size of manufacturing equipment, heat energy, and heating time substantially necessary for forming the reactor 2.

  Moreover, in the said manufacturing method, since the reactor 2 is fixed to the accommodating part 31 of the case 3 according to the said shrink fitting process, the reactor 2 can be fixed in the case 3 easily and reliably.

  Further, the reactor 2 has a substantially cylindrical shape, and the accommodating portion 311 has a substantially cylindrical shape along the shape of the reactor 2. Thereby, the reactor 2 can be tightened substantially uniformly from the outer periphery by the accommodating portion 311. Therefore, the reactor 2 can be stably fixed in the case 3.

  As described above, according to this example, it is possible to provide a power conversion device and a method for manufacturing the same that can reduce the size of manufacturing equipment and reduce the manufacturing cost.

(Example 2)
In this example, as shown in FIG. 6, convex or concave positioning means that are engaged with each other are provided on the outer peripheral surface of the reactor 2 and the inner side surface of the accommodating portion 31.
That is, convex portions 231 are provided at two locations on the outer peripheral surface of the reactor 2, and concave portions 312 corresponding to the convex portions 231 are provided at two locations on the inner surface of the housing portion 31.
And the reactor 2 is being fixed to the accommodating part 31 in the state which made the convex part 231 fit to the recessed part 312. FIG.
Others are the same as in the first embodiment.

In the case of this example, the reactor 2 can be prevented from being displaced in the housing portion 31. Therefore, even when an external force such as vibration acts on the power converter 1, it is possible to prevent the position of the reactor 2 from being displaced.
Others are the same as in the first embodiment.

(Example 3)
In this example, as shown in FIG. 7, continuous concave and convex surfaces 232 and 313 are respectively formed on the outer peripheral surface of the reactor 2 and the inner side surface of the accommodating portion 31.
And the uneven surface 232 of the reactor 2 and the uneven surface 313 of the accommodating part 31 are mutually closely_contact | adhered.
Others are the same as in the first embodiment.

In the case of this example, the contact area of the reactor 2 and the accommodating part 31 can be enlarged. Thereby, it becomes easy to radiate the heat of the reactor 2 to the case 3 through the accommodating part 31, and cooling efficiency improves.
Further, similarly to the second embodiment, the position shift of the reactor 2 can be prevented.
In addition, the same effects as those of the first embodiment are obtained.

Example 4
In this example, as shown in FIGS. 8 and 9, the accommodating portion 31 is configured by a frame 310 having a substantially constant thickness.
As for the accommodating part 31, the frame 310 which comprises the side part has at least substantially constant thickness. Moreover, it is preferable that the frame 310 which comprises a bottom face also has substantially the same thickness as the frame 310 which comprises a side part.
Others are the same as in the first embodiment.

In the case of this example, as shown in FIGS. 9A and 9B, when the accommodating portion 31 contracts in the shrink fitting process, the shrinkage dimension varies depending on the part of the frame 310 of the accommodating portion 31. Can be prevented. Thereby, the frame 310 of the accommodating part 31 can fasten the reactor 2 from the outer periphery with substantially equal pressing force, and can stably fix the reactor 2.
In addition, the same effects as those of the first embodiment are obtained.

(Example 5)
In this example, as shown in FIG. 10, the shape of the reactor 2 and the shape of the accommodating portion 31 are rectangular parallelepiped shapes. In this case, considering the contraction of the housing portion 31 during shrink fitting, the shapes of the reactor 2 and the housing portion 31 are preferably substantially square in plan view.
Others are the same as in the first embodiment.
Also in this example, it has the same effect as Example 1.

(Example 6)
This example is an example of the power conversion device 1 in which the reactor 2 is sandwiched and fixed between a plurality of cooling pipes 51 as shown in FIGS. 11 and 12.
The power conversion device 1 is provided with a semiconductor module 6 containing a semiconductor element and a cooler 5 for cooling the semiconductor module 6. The reactor 2 is sandwiched between a plurality of cooling pipes 51 constituting the cooler 5.

The semiconductor module 6 is also sandwiched between the cooling pipes 51. The plurality of cooling pipes 51 are connected to each other by connecting pipes 52 at both ends thereof. As a result, the cooling medium introduced from the refrigerant inlet 531 is distributed and supplied to each cooling pipe 51 through the connection pipe 52. The cooling medium that has passed through each cooling pipe 51 is configured to be discharged from the refrigerant outlet 532 through the connecting pipe 52.
The plurality of cooling pipes 51, the semiconductor modules 6, and the reactors 2 are alternately stacked and are pressed in the stacking direction by the leaf springs 12. Thereby, the cooling pipe 51 is sufficiently in close contact with the semiconductor module 6 and the reactor 2.

The reactor 2 is formed by integrally molding a metal member 24 made of aluminum or the like. The metal member 24 has an exposed portion 241 exposed on the bottom surface and a pair of side surfaces of the reactor 2, and an embedded portion 242 embedded in the core 22 inside the coil 21.
That is, the exposed portion 241 of the metal member 24 is exposed on the surface of the reactor 2 that does not contact the cooling pipe 51. A part of the metal member 24 is in contact with the cooling pipe 51.
Moreover, the reactor 2 is arrange | positioned in the state mounted in the bottom face 33 of case 3 of the power converter device 1. FIG.

When the reactor 2 is provided in the case 3 of the power converter 1, first, a molding process for molding the reactor 2 using a molding die 4 different from the case 3 is performed (see FIG. 2). At this time, the metal member 24 is inserted into the core 22 and molded.
Then, the clamping process which clamps the reactor 2 between the cooling pipes 51 is performed. At this time, a part of the metal member 24 is brought into contact with the cooling pipe 51.
Others are the same as in the first embodiment.

Next, the function and effect of this example will be described.
In the method for manufacturing the power conversion device of this example, the reactor 2 is disposed in the case 3 of the power conversion device 1 by performing the molding step and the clamping step. That is, similarly to the first embodiment, first, the reactor 2 is molded by the molding die 4 different from the case 3 in the molding step. Therefore, it is possible to reduce the size of manufacturing equipment such as a curing furnace for curing the magnetic powder mixed resin constituting the core 22 of the reactor 2, and also to reduce the heating energy. Can be shortened.

  In the above manufacturing method, the reactor 2 is sandwiched between the plurality of cooling pipes 51 by the sandwiching step, so that the reactor 2 can be easily and reliably fixed in the case 51. Moreover, the cooling efficiency of the reactor 2 can also be improved.

Moreover, since the reactor 2 integrally forms the metal member 24 exposed on the surface not in contact with the cooling pipe 31 and a part of the metal member 24 is in contact with the cooling pipe 31, the cooling efficiency of the reactor 2 is improved. Can do.
That is, if the metal member 24 is not provided, it is difficult to dissipate heat from the reactor 2 from a surface direction that does not contact the cooling pipe 51 that sandwiches the reactor 2. Therefore, the metal member 24 is integrally formed on this surface and brought into contact with the cooling pipe 51, whereby the heat of the reactor 2 can be radiated to the cooling pipe 51 through the metal member 24.

  As described above, according to this example, it is possible to provide a power conversion device and a method for manufacturing the same that can reduce the size of manufacturing equipment and reduce the manufacturing cost.

(Example 7)
In this example, as shown in FIG. 13 and FIG. 14, the reactor 2 is fixed to the reactor accommodating portion 31 provided in the case 3 by the bolt 14, and between the inner surface of the accommodating portion 31 and the reactor 2. This is an example of the power conversion device 1 in which a gap is filled with a resin 13 different from the core 22.
As shown in FIG. 13, the reactor 2 is molded in a state where a holed member 25 provided with a bolt insertion hole 251 is inserted. And as shown in FIG. 14, the reactor 2 is fastened by the accommodating part 31 with the volt | bolt 14 penetrated to the volt | bolt penetration hole 251 of the member 25 with a hole.

The holed member 25 is embedded inside the core 21 so as to penetrate the core 22. As a result, a bolt insertion hole 251 that penetrates the reactor 2 in the axial direction is provided in the reactor 2 inside the core 21. The holed member 25 is made of a metal material such as aluminum.
Further, the holed member 25 is in close contact with the bottom surface of the accommodating portion 31 at one end thereof.

As shown in FIGS. 13 and 14, screw holes 314 are provided in the frame 310 constituting the bottom surface of the housing portion 31, and the bolts 14 are screwed into the screw holes 314.
Further, as shown in FIG. 14, the resin 13 different from the core 22 is filled in the gap between the inner surface of the accommodating portion 31 and the reactor 2. The resin 13 is disposed between the side surface and the bottom surface of the reactor 2 and the inner side surface of the housing portion 31. As the resin 13, for example, a resin having excellent thermal conductivity and excellent flexibility such as urethane and silicone is used.

When the reactor 2 is provided in the case 3 of the power conversion device 1, first, a molding process is performed in which the reactor 2 is molded using a molding die 4 (FIG. 2) different from the case 3. At this time, the holed member 25 is molded in a state of being inserted into the core 22 inside the coil 21.
Next, a fixing process of fixing the reactor 2 with the bolts 14 to the reactor accommodating portion 31 provided in the case 3 is performed. At this time, the bolt 14 is inserted into the bolt insertion hole 251 of the holed member 25, and the bolt 14 is screwed into the screw hole 314 provided in the bottom surface of the accommodating portion 31.
Next, a resin filling step of filling the resin 13 in the gap between the inner side surface of the accommodating portion 31 and the reactor 2 is performed.
As described above, the reactor 2 is fixed to the accommodating portion 31 in the case 3 as shown in FIG.

Next, the function and effect of this example will be described.
In the method for manufacturing the power converter, the reactor 2 is disposed in the case 3 of the power converter 1 by performing the molding step, the fixing step, and the resin filling step. That is, similarly to the first embodiment, first, the reactor 2 is molded by the molding die 4 different from the case 3 in the molding step. Therefore, it is possible to reduce the size of the manufacturing equipment such as a curing furnace for curing the magnetic powder mixed resin constituting the core 21 of the reactor 2, and to reduce the heating energy. Can be shortened.

Moreover, in the said manufacturing method, since the reactor 2 is fixed to the case 3 according to the said fixing process, the reactor 2 in the case 3 can be fixed easily and reliably.
Further, in the manufacturing method, the resin 13 is filled in the gap between the inner surface of the housing portion 31 and the reactor 2 in the resin filling step. Therefore, heat transfer from the reactor 2 to the case 3 can be improved, and the cooling efficiency of the reactor 2 can also be improved.

Further, by interposing the resin 13 between the case 3 and the reactor 2, it is possible to absorb the vibration of the reactor 2 and suppress the vibration from being transmitted to the case 3.
In addition, since there is the resin filling step, it is possible to ensure a sufficient clearance between the housing portion 31 of the case 3 and the reactor 2, and facilitate the placement of the reactor 2 in the housing portion 31. Is possible.

  The reactor 2 is formed by inserting a holed member 25 provided with a bolt insertion hole 251, and is fastened to the housing portion 31 by a bolt 14 inserted into the bolt insertion hole 251 of the holed member 25. Thereby, the reactor 2 can be fixed to the accommodating part 31 of the case 3 easily and reliably. In addition, by configuring the holed member 25 with a member having excellent thermal conductivity such as aluminum, the heat of the reactor 2 can be radiated to the case 3 via the holed member 25, and the heat dissipation efficiency is excellent. Reactor 2 can be obtained.

  As described above, according to this example, it is possible to provide a power conversion device and a method for manufacturing the same that can reduce the size of manufacturing equipment and reduce the manufacturing cost.

(Example 8)
In this example, as shown in FIG. 15, the reactor 2 is fixed to the reactor accommodating portion 31 provided in the case 3 by the spring 15, and in the gap between the inner surface of the accommodating portion 31 and the reactor 2, This is an example of the power conversion device 1 filled with a resin 13 different from the core 22.
The spring 15 is fixed at its end to a frame 310 constituting the housing part 31 by a screw 16 and is biased so as to press the reactor 2 against the housing part 31 at the central part 151 of the spring 15. .

That is, in this example, instead of fixing with the bolt 14 in the seventh embodiment, fixing with a spring is performed. Therefore, the reactor 2 is fixed by the spring 15 in the fixing step shown in the seventh embodiment.
Moreover, it is not necessary to insert the holed member 25 (refer FIG. 13, FIG. 14) etc. in the reactor 2 especially.
The molding process and resin filling process are the same as in Example 7.
Others are the same as in the first embodiment.
Also in the case of this example, the reactor 2 can be fixed to the accommodating portion 31 of the case 3 easily and reliably. In addition, the same effects as those of the first embodiment are obtained.

Example 9
In this example, as shown in FIG. 16, the groove 26 is continuously formed in the axial direction on the outer peripheral surface of the reactor 2. This example is a modification of the aspect shown in Example 7 or Example 8.
A longitudinal resin flow space 17 is formed between the groove portion 26 and the inner side surface of the accommodating portion 31. The groove 26 is formed over the entire axial length of the reactor 2.
A plurality of groove portions 26 are preferably formed, but only one may be used.
Others are the same as in Example 7.

In the case of this example, in the resin filling step, the resin 15 can be smoothly filled between the inner surface of the housing portion 31 and the reactor 2. That is, in injecting the resin 15 into the gap between the inner surface of the housing portion 31 and the reactor 2, the resin 15 is passed through the resin flow space 17 between the groove portion 26 and the inner surface of the housing portion 31. It can penetrate smoothly to the bottom. Thereby, the resin 15 can be smoothly circulated and filled in the entire gap between the reactor 2 and the inner side surface of the housing portion 31. As a result, it is possible to prevent air from entering between the reactor 2 and the accommodating portion 31, ensure good heat transfer between the reactor 2 and the case 3, and improve cooling efficiency.
In addition, the same effects as those of the seventh embodiment are obtained.

(Example 10)
In this example, as shown in FIG. 17, the coil 21 and the core 22 are accommodated in the reactor case 30, and the vibration damping that has thermal conductivity is formed in the gap between the inner surface of the reactor case 30 and the core 22. It is an example of the reactor 20 which has arrange | positioned the material 71. FIG.
The reactor case 30 and the core 22 are not in direct contact.

  The damping material 71 is made of a material having a higher thermal conductivity than the core 22. Specifically, the damping material 71 is made of a resin mixed with a metal filler. As the resin, urethane, epoxy, silicon, or the like can be used.

  Further, an inner core 250 is embedded in the core 22 inside the coil 21 so as to penetrate in the axial direction of the coil 21. A damping material 72 is interposed between the core 250 and the reactor case 30. As the damping material 72, for example, a damping steel plate in which a resin is disposed between a pair of metal plates, a heat dissipation sheet made of silicon, a resin, or the like can be used.

Further, the core 250 is provided with a bolt insertion hole 251 for inserting the bolt 14. The core 22 is fixed to the reactor case 30 via the core 250 by fastening the fastening member inserted into the bolt insertion hole 251 to the reactor case 30.
In this example, a boss portion 34 protruding from the bottom surface of the reactor case 30 to the inside of the case is formed, and a female screw portion 341 is formed on the boss portion 34. The core 22 is fastened to the reactor case 30 by screwing the bolt 14 into the female screw portion 341. A vibration damping material 72 is interposed between the center core 250 and the boss portion 34.

  In this example, a damping material 71 is disposed between the core 22 and the reactor case 30 and between the bottom surface 252 of the core 250 and the reactor case 30, and the core 250 and the boss 34 In the above example, another damping material 72 different from the damping material 71 is shown. However, the damping material 71 and the damping material 72 can be made of the same material.

  Reactor case 30 has a thickness equal to or greater than the skin effect depth determined by the drive frequency of reactor 20 and the material of reactor case 30. For example, when the reactor case 30 is made of aluminum and the drive frequency is 10 kHz, the skin effect depth is 0.84 mm. Therefore, the thickness t of the reactor case 30 is 0.84 mm or more.

Next, the function and effect of this example will be described.
In the reactor 20, the reactor case 30 and the core 22 are not in direct contact. Therefore, the vibration transmission path from the core 22 to the reactor case 30 can be reduced, and the vibration of the core 22 can be prevented from being transmitted to the outside of the reactor 20 via the reactor case 30.

  Further, a damping material 71 having thermal conductivity is disposed in the gap between the inner surface of the reactor case 30 and the core 22. Therefore, the heat of the core 22 can be transmitted to the reactor case 30, and the heat dissipation of the reactor 20 can be sufficiently ensured. Further, by absorbing the vibration of the core 22 by the damping material 71, vibration transmission to the reactor case 30 can be suppressed.

Moreover, since the damping material 71 has higher thermal conductivity than the core 22, the heat of the core 22 can be efficiently transmitted to the reactor case 30 via the damping material 71, and thus the heat dissipation of the reactor 20. Can be further improved.
Further, since the damping material 71 is made of resin, the damping material 71 can be easily disposed between the inner surface of the reactor case 30 and the core 22. That is, for example, after placing and fixing the core 22 with the coil 21 inside the reactor case 30, the molten resin is poured between the reactor case 30 and the core 22, and this is cured, thereby being easily controlled. A vibration material 71 can be provided.

  Further, since the damping material 72 is interposed between the core 250 embedded in the core 22 inside the coil 21 and the reactor case 30, the vibration of the core 22 is transmitted to the reactor case 30 through the core 250. Can be suppressed.

  Moreover, since the reactor case 30 has a thickness t equal to or greater than the skin effect depth, the magnetic flux generated by the coil 21 can be prevented from leaking out of the reactor case 30. Thereby, it can prevent affecting the electronic device arrange | positioned around the reactor 20. FIG.

  Further, since the reactor case 30 is made of a non-magnetic material, it can prevent a magnetic circuit of magnetic flux generated by the reactor 20 from being affected and can form a desired magnetic circuit. As a result, the inductance of the reactor 20 can be improved. That is, when the reactor case 30 is made of a magnetic material, there is a possibility that an eddy current may be generated by the magnetic flux passing through the case, thereby affecting the magnetic circuit. However, the reactor 20 is made of a non-magnetic material. This can be prevented.

  In this example, the reactor case 30 is formed so as to cover the entire surface of the core 22 by disposing a lid on the upper portion (the opening of the upper reactor case 30 in FIG. 17). (See FIGS. 21 and 22). In this case, leakage of magnetic flux generated by the coil 21 can be prevented in all directions.

(Example 11)
This example is an example of the reactor 20 in which any one or both of the vibration damping materials 71 and 72 are made of a metal plate having a hardness lower than that of the core 22.
The metal plate is made of, for example, aluminum and embossed.
Others are the same as in Example 10.

In the case of this example, the drying and curing steps required when the damping materials 71 and 72 are made of resin are not required, so that the manufacturing process can be simplified and the cost can be reduced. it can. As a result, an easily manufactured and inexpensive reactor can be obtained.
Further, since the vibration damping materials 71 and 72 are embossed, the vibration of the core 22 can be absorbed in the embossed portion, and the vibration transmission of the reactor 20 can be further suppressed.
In addition, the same effects as those of the tenth embodiment can be achieved.

(Example 12)
In this example, as shown in FIG. 18, the bottom plate 35 of the reactor case 30 is increased in thickness, and the female screw portion 341 is provided on the bottom plate 35.
Then, the bottom surface 352 of the core 250 is brought into contact with the bottom plate 35 of the reactor case 30 via the vibration damping material 72.
Others are the same as in Example 10.
In the case of this example, it is not necessary to provide the boss portion 34 (see FIG. 17) shown in the tenth embodiment in the reactor case 30, and therefore the reactor case 30 can be easily formed.
In addition, the same effects as those of the tenth embodiment are achieved.

(Example 13)
In this example, as shown in FIGS. 19 to 27, four types of reactors 20 are produced, and the magnitude of vibration and heat dissipation are compared.
As shown in FIG. 19, the core 22 was formed integrally with the reactor case 30 as shown in FIG. 19, and a reactor in which the core 22 was in close contact with the inner side surface of the reactor case 30 was produced.
As shown in FIG. 20, as shown in FIG. 20, a core 22 manufactured separately was fixed in the reactor case 30, and a reactor having a gap between the core 22 and the reactor case 30 was manufactured.
As shown in FIG. 21, as shown in FIG. 21, the damping material 71 is interposed only between the core 22 manufactured separately and the center core 250 embedded inside the core 22 and the bottom plate 35 of the reactor case 30. A reactor was made. Here, the damping material 71 is made of silicon.
As shown in FIG. 22, as shown in FIG. 22, a reactor in which a damping material 71 was interposed between the entire circumference of the core 22 and the bottom surface 252 of the core 250 and the reactor case 30 was manufactured. . Here, the damping material 71 is made of urethane or silicon mixed with a metal filler.

In these samples, the reactor case 30 and the core 250 are made of aluminum.
And about each sample, the following vibration test was done in multiple times.
In the vibration test, a high frequency current is passed through the coil of each sample (reactor) to drive the reactor. At this time, the current is 80 A, the voltage is 650 V, and the frequency is 9.55 kHz. In this state, the vibration in the reactor case 30 was measured.
The measurement of vibration was performed for the vibration in the left-right direction (X direction), the vibration in the depth direction (Y direction), and the vibration in the vertical direction (Z direction) in FIGS. Each vibration was evaluated by acceleration. In each figure, the vertical axis represents vibration acceleration, and the horizontal axes X, Y, and Z represent the directions of vibrations measured, respectively. Note that the unit of the vertical axis is G, which is gravitational acceleration.

The measurement results are shown in FIGS. FIG. 23 shows the measurement result of Sample 1, FIG. 24 shows the measurement result of Sample 2, FIG. 25 shows the measurement result of Sample 3, and FIG.
As can be seen from the measurement results, the sample 1 has a large vibration, particularly in the Z direction, the vibration magnitude is much larger than 3G, whereas the sample 2 has a vibration of less than 2G and the samples 3 and 4 The vibration is suppressed to less than 1G.
That is, when the core 22 is formed integrally with the reactor case 30 as in the sample 1 and the core 22 and the reactor case 30 are in direct contact with each other, the vibration of the core 22 is greatly transmitted to the reactor case 30. However, like the samples 2 to 4, the core 22 and the reactor case 30 are individually manufactured and the two are not in direct contact with each other, whereby the vibration of the reactor case 30 can be greatly suppressed.

  Next, the heat dissipation performance of each sample was evaluated. For sample 4, four types of samples were prepared by changing the amount of the metal filler in the damping material 71 and changing the thermal conductivity. Specifically, reactors using damping materials 71 having thermal conductivity 0.25 times, 0.5 times, 1 time, and 1.25 times that of the core 22 are used as Sample 4-1, Sample 4-2, respectively. Sample 4-3 and sample 4-4. In Sample 4-1, Sample 4-2, and Sample 4-3, urethane was used as the damping material 71, and silicon was used as the damping material 71 in Sample 4-4. Further, the heat dissipation sheet in the reactor of the sample 3 has a thermal conductivity three times that of the core 22.

And the saturation temperature of the reactor when the current of 39A, 45A, and 55A was continued to flow through each sample suitably was measured. The measurement results are shown in FIG.
In addition, with respect to the sample 2, since the temperature rose significantly above the standard upper limit of 150 ° C. by continuing energization, the saturation temperature could not be measured.
The results for Sample 1 to Sample 4-4 were designated P1 to P4-4, respectively.

  As can be seen from FIG. 27, for samples other than sample 2, the saturation temperature can be suppressed to 150 ° C. or lower, which is the standard upper limit value. In Sample 4-1 to Sample 4-4, which are provided with damping material 71 around the entire circumference between core 22 and reactor case 30, damping material 71 is provided only on bottom plate 35 of reactor case 30. Compared with the sample 3, the heat dissipation can be greatly improved. And by increasing the thermal conductivity of the damping material 71, the heat dissipation is also improved, and especially by making the thermal conductivity 1.25 times that of the core 22 as in the sample 4-4, The heat dissipation equal to or higher than that of the sample 1 integrally provided with the reactor case 30 can be ensured.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective explanatory view showing a method for manufacturing a power conversion device in Embodiment 1. Sectional explanatory drawing which shows the shaping | molding method of the reactor in Example 1. FIG. Explanatory drawing of the shrink fitting process in Example 1. FIG. Plane explanatory drawing of the shrink fitting process in Example 1. FIG. Plane explanatory drawing of the power converter device in Example 1. FIG. The top view of the reactor fixed to the accommodating part in Example 2. FIG. The top view of the reactor fixed to the accommodating part in Example 3. FIG. FIG. 10 is a perspective explanatory view of a part of the case of the power conversion device according to the fourth embodiment. Plane explanatory drawing of the shrink-fitting process in Example 4. FIG. FIG. 10 is an explanatory perspective view illustrating a method for manufacturing a power conversion device according to a fifth embodiment. Plane explanatory drawing of the power converter device in Example 6. FIG. FIG. 12 is a cross-sectional view taken along line AA in FIG. 11. Sectional explanatory drawing which shows the manufacturing method of the power converter device in Example 7. FIG. Sectional explanatory drawing of the power converter device in Example 7. FIG. Sectional explanatory drawing of the power converter device in Example 8. FIG. In Example 9, (A) The top view of the reactor arrange | positioned in the accommodating part, (B) The side view of a reactor. Sectional explanatory drawing of the reactor in Example 10. FIG. Sectional explanatory drawing of the reactor in Example 12. FIG. Sectional explanatory drawing of the sample 1 in Example 13. FIG. Sectional explanatory drawing of the sample 2 in Example 13. FIG. Sectional explanatory drawing of the sample 3 in Example 13. FIG. Sectional explanatory drawing of the sample 4 in Example 13. FIG. The diagram of the vibration test result about the sample 1 in Example 13. FIG. The diagram of the vibration test result about sample 2 in Example 13. The diagram of the vibration test result about the sample 3 in Example 13. FIG. The diagram of the vibration test result about sample 4 in Example 13. The diagram of the heat dissipation test result in Example 13.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Power converter 13 Resin 2 Reactor 21 Coil 22 Core 3 Case 31 Storage part 4 Molding die 5 Cooler 51 Cooling pipe 6 Semiconductor module

Claims (25)

A method of manufacturing a power converter having a built-in reactor having a coil that generates a magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil,
In providing the reactor in the case of the power converter,
After the coil and the magnetic powder mixed resin are arranged in a molding die different from the case , the magnetic powder mixed resin is thermoset to mold the reactor,
After thermally expanding the reactor accommodating portion provided in the case, the reactor taken out from the mold is disposed in the accommodating portion, and then the accommodating portion is cooled and contracted, The manufacturing method of the power converter device which performs the shrink fitting process which fixes the said reactor to an accommodating part.   2. The method of manufacturing a power conversion device according to claim 1, wherein the reactor has a substantially cylindrical shape, and the housing portion has a substantially cylindrical shape along the shape of the reactor.   3. The method of manufacturing a power conversion device according to claim 2, wherein convex or concave positioning means that engage with each other is provided on the outer peripheral surface of the reactor and the inner side surface of the housing portion.   The method for manufacturing a power conversion device according to claim 1, wherein the housing portion is configured by a frame having a substantially constant thickness. A reactor having a coil that generates a magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil; a semiconductor module containing a semiconductor element; and a cooler that cools the semiconductor module. A method of manufacturing a power converter having
The cooler is formed by arranging a plurality of cooling pipes and connecting the cooling pipes at both ends by connecting pipes.
In providing the reactor in the case of the power converter,
A molding step of molding the reactor using a molding die different from the case;
The reactor, a manufacturing method of a plurality of between the connecting pipe, a power conversion apparatus characterized by performing a clamping step of clamping during the cooling tube of the upper Kifuku number.   6. The method of manufacturing a power conversion device according to claim 5, wherein the reactor is formed by integrally forming a metal member exposed on a surface not in contact with the cooling pipe, and a part of the metal member is brought into contact with the cooling pipe. . A method of manufacturing a power converter having a built-in reactor having a coil that generates a magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil,
In providing the reactor in the case of the power converter,
A molding step of molding the reactor using a molding die different from the case;
A fixing step of fixing the reactor to the reactor housing provided in the case;
There lines and a resin filling step of filling the resin into the gap between the inner surface and the reactor of the accommodating portion,
In the molding step, the reactor is molded while inserting a holed member provided with a bolt insertion hole inside the coil, and in the fixing step, a bolt inserted into the bolt insertion hole of the holed member is used. A method of manufacturing a power converter, wherein the reactor is fastened to the housing portion .   8. The method of manufacturing a power conversion device according to claim 7, wherein a groove is continuously formed in the axial direction on the outer peripheral surface of the reactor. A power conversion device having a built-in reactor having a coil that generates magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil,
The power converter according to claim 1, wherein the reactor is fixed by shrink fitting to the reactor accommodating portion provided in the case, and is pressed and tightened from the outer periphery to the accommodating portion . The power converter according to claim 9, wherein the reactor has a substantially cylindrical shape, and the housing portion has a substantially cylindrical shape along the shape of the reactor. 11. The power conversion device according to claim 10 , wherein convex or concave positioning means that engage with each other is provided on the outer peripheral surface of the reactor and the inner side surface of the housing portion. The method for manufacturing a power conversion device according to claim 9, wherein the housing portion is configured by a frame having a substantially constant thickness. A reactor having a coil that generates a magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil; a semiconductor module containing a semiconductor element; and a cooler that cools the semiconductor module. A power conversion device comprising:
The cooler is formed by arranging a plurality of cooling pipes and connecting the cooling pipes at both ends by connecting pipes.
The reactor is sandwiched between the plurality of cooling pipes among the plurality of connecting pipes . 14. The power conversion according to claim 13, wherein the reactor is integrally formed with a metal member exposed on a surface that does not contact the cooling pipe, and a part of the metal member is in contact with the cooling pipe. apparatus. A power conversion device having a built-in reactor having a coil that generates magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and outside the coil,
The reactor is fixed to the reactor accommodating portion provided in the case,
The gap between the inner surface of the housing part and the reactor is filled with a resin different from the core ,
The reactor is molded in a state where a holed member provided with a bolt insertion hole is inserted inside the coil, and is fastened to the housing portion by a bolt inserted into the bolt insertion hole of the holed member. power converter, characterized in that is. 16. The power conversion device according to claim 15, wherein a groove is continuously formed in the axial direction on the outer peripheral surface of the reactor. A reactor in which a coil that generates magnetic flux when energized and a core made of a magnetic powder mixed resin filled inside and around the coil are housed in a reactor case,
In the gap between the inner surface of the reactor case and the core, a damping material having thermal conductivity is disposed, and the reactor case and the core are not in direct contact ,
In the core inside the coil, a core disposed so as to penetrate in the axial direction of the coil is embedded in contact with the core, and between the core and the reactor case. Is a reactor in which the vibration damping material is interposed . The reactor according to claim 17, wherein the damping material has higher thermal conductivity than the core. The reactor according to claim 17 or 18, wherein the vibration damping material is made of resin. 19. The reactor according to claim 17, wherein the damping material is made of a metal plate having a hardness lower than that of the core. The reactor according to claim 20, wherein the damping material is embossed. The reactor according to any one of claims 17 to 21 , wherein the reactor case has a thickness equal to or greater than a skin effect depth determined by a driving frequency of the reactor and a material of the reactor case. 23. The reactor according to any one of claims 17 to 22 , wherein the reactor case is made of a nonmagnetic material. The reactor according to any one of claims 17 to 23 , wherein the reactor case is formed so as to cover the entire surface of the core. It is a power converter device carrying the reactor as described in any one of Claims 17-24 , Comprising: The said reactor case is a part of case of the said power converter device, The power converter device characterized by the above-mentioned.

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