JP5332527B2 - Reactor device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor apparatus which secures damping property and heat dissipation, and prevents the overflow of resin by reliably filling a damping material up to a required range. <P>SOLUTION: The reactor apparatus 1 includes a reactor 4 having a coil 2 generating a magnetic flux by energization and a core 3 consisting of a magnetic powder mixed resin filled up in the inside and periphery of the coil 2, a case 9 having a housing 5 to house the reactor 4, and a resin 6 intervening in a gap between an interior side 5c of the housing 5 and the outer surface 4a of the reactor 4, wherein a pool 5f of the damping material is provided in the housing 5. By this arrangement, in the filling-up process of the resin 6, the resin 6 never overflows from the housing 5 even in a place where the resin 6 crawls up locally, the resin 6 becoming excessive here is charged to the place where it does not crawl up to a desired height, hence filling-up height becomes uniform, the gap equal or lower than the pool 5f is reliably filled up. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

  The present invention relates to a reactor device.

  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.

  This power conversion device includes a semiconductor module that forms part of the power conversion circuit, a cooler that cools the semiconductor module, and a reactor that forms part of the boost circuit for boosting the input voltage. It is stored in the case.

  As the reactor, for example, as disclosed in Patent Document 1, there is 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 core is formed by pouring a liquid magnetic powder mixed resin into a mold and then solidifying the magnetic powder mixed resin by heating. At this time, a holed member provided with a bolt insertion hole is embedded in the center of the reactor, and the reactor is fixed to the reactor accommodating portion provided in the case by a bolt penetrating the hole.

Here, the gap between the inner side surface of the housing portion and the outer surface of the reactor is filled with a resin different from the core from the viewpoint of vibration damping and heat dissipation. By injecting the resin into the bottom surface of the case housing portion of the reactor in advance, when the reactor is inserted into the housing portion, the resin is crushed by the bottom of the reactor and crawls up the gap between the inner surface of the housing portion and the outer surface of the reactor. In this way, the resin is filled.
JP 2008-198981 A

  However, in manufacturing, in the above resin filling step, since the gap between the reactor and the inner surface of the housing portion is narrow, there is a concern that the end surface on the opening side of the resin becomes non-uniform. If the resin is not filled to the required range, the support of the reactor may be insufficient and vibration may not be sufficiently suppressed, and the heat dissipation efficiency of the reactor may be deteriorated. Moreover, there is a possibility that the resin spills locally and the resin overflows from the accommodating portion.

The present invention has been made based on the above circumstances, and its purpose is to reliably fill the resin to the required range to ensure vibration damping and heat dissipation and to prevent the resin from overflowing. To provide a reactor device.
(Invention of Claim 1)
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 on the outer periphery of the coil, and an accommodating portion that accommodates a reactor having an opening on one side and a bottom surface on the other. In the reactor device comprising a vibration damping member interposed in a gap between the inner side surface of the housing portion and the outer surface of the reactor, the inner side surface of the housing portion has a support portion that supports the reactor via the vibration damping member, and an opening. And a stepped portion provided between the support portion and the damping member reservoir, the stepped portion having a gap between the support portion and the outer surface of the reactor larger than the support portion. , Provided on the opening side from the terminal side end surface of the coil , and on the bottom side from the end side end surface of the core, and the damping member reservoir is provided on the opening side from the terminal side end surface of the coil. The damping member is a step Characterized in that it is filled to the remote opening side.

According to the present invention, in the step of filling the damping member in the gap between the inner surface of the housing part and the outer surface of the reactor by forming the damping member reservoir in the opening of the housing part, the opening side end surface of the damping member The position can be made uniform. That is, in a place where the vibration damping member locally climbs up, the excess vibration damping member accumulates in the reservoir portion, so there is no possibility of overflowing from the accommodating portion. Further, in a place where the vibration damping member does not crawl up to the pool part, an extra vibration damping member in another place is transmitted along the circumferential direction of the pool part and compensated. Thereby, since the damping member is uniformly filled, the transmission of vibration can be suppressed by reliably supporting the reactor in the housing portion. Moreover, since the damping member also has a function of transmitting the heat of the reactor to the case, heat dissipation can be ensured.
Step difference unit is characterized in that provided in the opening portion than the terminal end face of the coil.

As a result, the damping member reservoir is positioned closer to the opening than the coil that is the heat generation source, so that the heat dissipation is not deteriorated by providing the reservoir in the housing. That is, since the gap near the coil is narrow and the resin 6 layer is thin, the heat of the coil can be efficiently transmitted to the case and radiated.
In the reactor device described above , the step portion is provided on the bottom surface side of the terminal side end surface of the reactor.

This can prevent the damping member from flowing into the terminal side end surface of the reactor in the damping member filling step.
(Invention of Claim 2 )
In Li Akutoru device according to claim 1, the step portion is characterized in that an inclined surface whose inner periphery decreases gradually accommodating portion toward the bottom surface side from the opening side of the housing portion.

By inclining the step on the inner side surface of the housing portion, when the reactor is inserted into the housing portion, the step is not caught by the step portion, so that the reactor assembly process can be facilitated.
(Invention of Claim 3 )
In reactor apparatus for placing serial to claim 1 or 2, the opening of the accommodating portion, the terminal end face of the reactor is characterized in that is provided so as to be the bottom side of the opening.

As a result, in the damping member filling process, even if the damping member locally and temporarily rises above the terminal-side end surface of the reactor, the damping member is surely prevented from overflowing outside the accommodating portion. it can.
(Invention of Claim 4 )
The reactor device according to any one of claims 1 to 3 , wherein the accommodating portion has a substantially cylindrical shape.

By making the housing part into a substantially cylindrical shape, the vibration damping member previously injected into the center of the bottom surface of the housing part in the damping member filling step is uniformly spread toward the outer surface of the reactor by being crushed by the bottom surface of the reactor. Therefore, it is easy to fill the damping member uniformly.
(Invention of Claim 5 )
The reactor device according to any one of claims 1 to 4 , wherein the damping member is urethane.

  Since urethane is excellent in elasticity, it is suitable for use as a vibration damping member of a reactor device, and also has excellent thermal conductivity, which contributes to improvement in the heat dissipation efficiency of the reactor. In addition, because of its excellent heat resistance, it can withstand the high temperature environment when the reactor is energized and maintain a stable damping effect.

  The best mode for carrying out the present invention will be described in detail with reference to the following examples.

The structure of the reactor apparatus which concerns on this invention is demonstrated.
As shown in FIG. 1, a reactor device 1 includes a reactor 4 having a coil 2 that generates a magnetic flux when energized, and a core 3 made of a magnetic powder mixed resin filled inside and outside the coil 2. And a damping member (resin 6 in the present embodiment) interposed in the gap between the accommodating portion 5 that accommodates the reactor 4 that has the bottom surface on the other side and the inner surface 5c of the accommodating portion 5 and the outer surface 4a of the reactor 4 Consists of.

  The coil 2 is formed by winding a plate-like conductor in a spiral shape, and as shown in FIG. 1, both ends thereof protrude from the spiral portion to form a pair of terminals 2a.

  As shown in FIG. 1, the core 3 is formed by curing a resin mixed with magnetic powder and covers the entire coil 2. By doing so, since the magnetic flux of the coil 2 passes through the magnetic powder mixed resin having a high magnetic permeability, the inductance value of the coil 2 can be increased. Here, 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 can be molded into the core 3. The core 3 is preferably substantially cylindrical.

  As shown in FIG. 1, the reactor 4 includes a coil 2 and a core 3, and the coil 2 is provided inside the core 3. Further, the pair of terminals 2 a of the coil 2 are provided so as to protrude from the core 3. Furthermore, a core 7 made of a metal material such as aluminum is embedded in the core 3 so as to penetrate the reactor 4 in the axial direction. The core 7 is provided with a bolt insertion hole 7a for inserting the bolt 8 and a recess 7b on the bottom side.

  As shown in FIG. 1, the accommodating portion 5 has a shape (substantially cylindrical shape in this example) along the shape of the reactor 4, and has an opening 5 b on one side and a bottom surface 5 d on the other side. As shown in FIG. 1, the inner surface 5 c of the housing portion 5 is a resin in which a gap between the support portion 5 e that supports the reactor 4 via the resin 6 and the reactor outer surface 4 a is larger than the support portion 5 e on the opening end side. 6 reservoirs 5f. Here, a step is generated between the support portion 5e and the reservoir portion 5f. The step portion 5g is closer to the opening portion 5b than the terminal-side end surface 2b of the coil and from the terminal-side end surface 4b of the reactor 4 to the bottom surface. In addition to being provided on the 5c side, an inclined surface is formed such that the inner periphery of the accommodating portion 5 gradually decreases from the opening end 5b side to the bottom surface 5c side. And the opening part 5b of the accommodating part 5 is provided so that the terminal side end surface 4b of a reactor may become the bottom face 5c side rather than the opening part 5b. Further, the bottom surface 5d is provided with a boss portion 5h protruding toward the opening 5b, and a female screw portion 5i is formed therein.

  The resin 6 is, for example, urethane, and is filled in a gap between the inner side surface 5c of the accommodating portion 5 and the outer surface 4a of the reactor 4 as shown in FIG.

  The reactor apparatus 1 having the above configuration is provided inside a case 9 as shown in FIG. The accommodating part 5 is provided inside the case 9 and inside the frame 5a having an outer shape of a rectangular parallelepiped shape. The case 9 is an inverter case and is made of a metal material such as aluminum. In the case 9, in addition to the reactor 4, a main circuit portion (not shown) including a plurality of semiconductor modules constituting a part of the power conversion circuit and a cooler for cooling the semiconductor modules is accommodated. Here, the reactor 4 is electrically connected to the main circuit unit and electrically connected to an external power source. The reactor 4 constitutes a part of a boosting unit that boosts a DC voltage supplied from a power source and sends it to the main circuit unit.

  Next, the manufacturing method of the reactor apparatus which concerns on this invention is demonstrated.

  The reactor 4 is molded by the following molding process.

  First, as shown in FIG. 3A, after the coil 2 and the core 7 are arranged at predetermined positions in the mold 10, liquid magnetic powder mixed resin is injected into the mold 10. Here, the pair of terminals 2a of the coil 2 protrude from the magnetic powder mixed resin.

  Next, the coil 2 and the magnetic powder mixed resin arranged in the mold 10 are put together with the mold 10 into a curing furnace and heated at a predetermined temperature for a predetermined time. As a result, the magnetic powder mixed resin is solidified to form the core 3 and the reactor 4 is formed. And the reactor 4 shape | molded and solidified in the shaping | molding die 10 is taken out from the shaping | molding die 10 as shown in FIG.3 (B).

  The resin 6 as the damping member is filled by the following filling process.

  As shown in FIG. 4, the resin 6 is injected into the bottom surface 5 d of the storage unit 5 in advance before the reactor 4 is assembled to the storage unit 5. The reactor 4 is inserted into the accommodating portion 5 so that the core recess portion 7b and the accommodating portion boss portion 5h are engaged while the bottom portion 4c crushes the resin 6. After the resin 6 spreads over the entire bottom surface 5d of the housing portion, the resin 4 is further expanded by being inserted deeply, and crawls up the gap between the housing inner side surface 5c and the reactor outer surface 4a. When the reactor 4 is inserted as far as the interior of the housing portion 5, the resin 6 scooping up the gap between the support portions 5e of the housing portion 5 locally reaches the housing portion reservoir 5f. Here, the opening 5b of the accommodating portion 5 is provided so that the terminal side end surface 4b of the reactor 4 is closer to the bottom surface 5c than the opening 5b, and thus temporarily than the terminal side end surface 4b of the reactor 4. The resin 6 that has been scooped up does not overflow to the outside of the housing portion 5 and accumulates in the reservoir portion 5f. Here, the excess resin 6 is supplemented to the portion where the resin 6 does not crawl up to the stepped portion 5g of the housing portion 5 along the collecting portion 5f in the circumferential direction. As a result, the unevenness of the resin 6 is eliminated, and the gap between the support portions 5e of the housing portion is uniformly filled.

After the filling step, as shown in FIG. 4, the reactor 4 is screwed into the housing portion 5 by the bolt 8 inserted through the core 7 being screwed into the female screw portion 5 i formed in the boss portion 5 h of the housing portion 5. Fixed.
(Effect of Example 1)
In the reactor device 1 according to the first embodiment, the storage portion 5 is formed with a reservoir portion 5f of the resin 6. Thereby, in the filling process of the resin 6, there is no fear that the resin 6 overflows from the housing part 5, and the resin 6 can be uniformly filled in the gaps of the support part 5e. For this reason, the reactor 4 is reliably supported by the accommodating part 5, and transmission of a vibration can be suppressed. Moreover, since the resin 6 also has a function of transmitting the heat of the reactor 4 to the case 9, heat dissipation can be ensured.

  Since the step portion 5g is provided closer to the opening 5b than the terminal-side end surface 2b of the coil 2, the reservoir 5f is located closer to the opening 5b than the coil 2 that is a heat source. The provision of the portion 5f does not deteriorate the heat dissipation. That is, since the gap near the coil 2 is narrow and the layer of the resin 6 is thin, the heat of the coil 2 can be efficiently transmitted to the case 9 to be radiated.

  Further, as shown in FIG. 5, the width of the gap between the accommodating portion support portion 5 e depends on the dimensional tolerance between the accommodating portion 5 and the reactor 4, and therefore the end surface 6 a on the opening 5 b side of the resin 6 varies. That is, the end surface on the opening end 5b side of the resin 6 is the highest (H1) when the width of the gap of the accommodating portion support portion 5e is the minimum C1, and conversely, the gap width of the accommodating portion support portion 5e is the maximum C2. Becomes the lowest (H2). Therefore, even when the end surface on the opening end 5b side of the resin 6 becomes the highest, the housing portion reservoir portion 5f is positioned closer to the bottom surface 6c than the terminal side end surface 4b of the reactor 4 (see FIG. 5A)). Moreover, even when the end surface on the opening end 5b side of the resin 6 is the lowest, the reactor device is set to a size that is closer to the opening end side than the support portion 5e of the housing portion 5 (see FIG. 5B). Regardless of the individual difference, the resin 6 can be filled in an appropriate range.

  Moreover, by making the level | step-difference part 5g of the accommodating part inner side surface 5c into a slope, it is easy to remove from a metal mold | die in the die-cast process of the accommodating part 5. FIG. Moreover, when inserting the reactor 4 in the accommodating part 5, since it does not catch on the level | step-difference part 5g, the assembly | attachment process of the reactor 4 can be made easy.

  Moreover, by making the accommodating part 5 into a substantially cylindrical shape, in the resin 6 filling step, the resin 6 previously injected into the center of the accommodating part bottom surface 5d is crushed by the reactor bottom part 4c toward the reactor outer surface 4a. Spread evenly. Therefore, it is easy to fill the resin 6 uniformly.

In addition, since urethane used for the resin 6 in this embodiment is excellent in elasticity, it is suitable for use as a vibration damping member of the reactor device 1 and also has excellent thermal conductivity, so that the heat dissipation efficiency of the reactor 4 can be improved. To contribute. Moreover, since it is excellent also in heat resistance, it can endure the high temperature environment at the time of energization of the reactor apparatus 1, and the stable vibration suppression effect is maintained.

(Modification)
In the reactor device 1 according to the first embodiment, the means for fixing the reactor 4 to the housing portion 5 may be a spring that presses the reactor upper end surface 4b. In this case, the core 7 is not necessary. Further, the stepped portion 5g of the accommodating portion 5 is a slope for easy manufacturing, but may be a right angle. In addition to urethane, the resin 6 may be a resin excellent in elasticity, thermal conductivity, and heat resistance, such as silicon.

It is sectional drawing of a reactor apparatus. It is an isometric view explanatory drawing which shows the reactor accommodated in a case. It is sectional explanatory drawing which shows the shaping | molding method of a reactor. It is sectional explanatory drawing which shows a damping member filling process. (A) It is sectional drawing of a reactor in case the damping member filling height is the maximum, (B) When the damping member filling height is the minimum.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Reactor apparatus 2 Coil 3 Core 4 Reactor 5 Accommodating part 5b Opening part 5c Inner side surface 5d Bottom part 5e Support part 5f Reservoir part 5g Step part 7 Damping member 9 Case 10 Mold

Claims (5)

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;
An accommodating portion for accommodating the reactor having an opening on one side and a bottom surface on the other;
In a reactor device comprising a vibration damping member interposed in a gap between the inner side surface of the housing part and the outer surface of the reactor,
The inner surface of the housing portion has a damping member reservoir that has a gap between a support portion that supports the reactor via the damping member and an opening portion side that is larger than the outer surface of the reactor than the support portion. And a step part provided between the support part and the damping member reservoir part,
The stepped portion is provided on the opening side of the terminal side end surface of the coil and on the bottom side of the opening side end surface of the core ,
The damping member reservoir is provided closer to the opening than the terminal side end face of the coil,
The reactor device is characterized in that the vibration damping member is filled to the opening side of the stepped portion. The reactor device according to claim 1,
The reactor is characterized in that the stepped portion is formed of an inclined surface in which the inner periphery of the housing portion gradually decreases from the opening side to the bottom surface side of the housing portion. The reactor device according to claim 1 or 2,
The reactor device is characterized in that the opening portion of the housing portion is provided such that a terminal side end surface of the reactor is closer to the bottom surface side than the opening portion. The reactor apparatus in any one of Claims 1-3 WHEREIN:
The reactor is characterized by having a substantially cylindrical shape. In any reactor device of Claims 1-4,
The reactor device is characterized in that the damping member is urethane.

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