JP5741405B2 - Reactor and manufacturing method thereof - Google Patents

Description

  The present invention relates to a reactor having a core in which magnetic powder is mixed with an insulating resin, and a manufacturing method thereof.

  Conventionally, a reactor including a core (so-called dust core) in which magnetic powder is mixed with an insulating resin and an electromagnetic coil embedded in the core is known (see Patent Document 1 below). An example of a conventional electromagnetic coil manufacturing method is shown in FIG.

  In the conventional method of manufacturing the reactor 9, first, a magnetic powder and a liquid insulating resin are placed in a large container 93 and mixed to manufacture a magnetic powder mixed resin 92. At this time, in order to make the magnetic characteristics of the reactor 9 constant, the concentration of the magnetic powder is adjusted. The magnetic powder is, for example, iron powder, and the insulating resin is a thermosetting resin such as an epoxy resin.

  Further, the electromagnetic coil 91 is accommodated in the accommodation case 90 of the reactor 9. Then, the magnetic powder mixed resin 92 in the container 93 is subdivided and placed in the housing case 90, and the electromagnetic coil 91 is filled with the magnetic powder mixed resin 92. Thereafter, heat is applied to cure the magnetic powder mixed resin 92 to form a core.

  When a plurality of reactors 9 are manufactured, the magnetic powder mixed resin 92 in the container 93 gradually decreases. When the container 93 is emptied, the magnetic powder and the insulating resin are put in the container 93 again and mixed to newly manufacture the magnetic powder mixed resin 92.

  However, this manufacturing method has a problem that when the container 93 is emptied, the remaining residue of the magnetic powder mixed resin 92 adheres to the inner surface 930 of the container 93. If the magnetic powder and the insulating resin are newly added to the container 93 with the remaining soot attached to the inner surface 930, it becomes difficult to adjust the concentration of the magnetic powder. Therefore, it is necessary to remove the remaining soot before putting the magnetic powder or the like into the container 93.

  If the process of removing the remaining soot is performed, the number of work steps increases, which causes the manufacturing cost of the reactor 9 to increase. Therefore, there is a demand for a method of manufacturing the reactor 9 that does not require the remaining soot removal step. For example, as shown in FIG. 12, a method for producing a magnetic powder mixed resin 92 in the housing case 90 by mixing and mixing magnetic powder and insulating resin in each housing case 90 has been studied. Then, the electromagnetic coil 91 is inserted into the produced magnetic powder mixed resin 92. In this way, since the container 93 is not used, the remaining residue of the magnetic powder mixed resin 92 is not generated, and it is not necessary to perform the removal operation of the remaining residue.

JP 2005-303034 A

  However, since the magnetic powder mixed resin 92 has a high viscosity, if an attempt is made to insert the electromagnetic coil 91 into the magnetic powder mixed resin 92, it is necessary to apply a strong force to the electromagnetic coil 91, and the electromagnetic coil 91 is easily damaged. Moreover, it takes a long time to insert the electromagnetic coil 91.

  The present invention has been made in view of such a background, and intends to provide a reactor capable of inserting an electromagnetic coil into a magnetic powder mixed resin in a short time and reducing a load applied to the electromagnetic coil, and a method for manufacturing the same. Is.

One embodiment of the present invention includes a core obtained by mixing magnetic powder with an insulating resin,
A cylindrical insert having a cylindrical electromagnetic coil wound with a conducting wire, inserted into the core, and
A housing case for housing the core and the insert,
At least one of the outer peripheral surface and the inner peripheral surface of the insert is formed with a spiral groove centered on the axis of the insert ,
The insert includes the electromagnetic coil and a coil case that houses the electromagnetic coil, and the groove is formed in at least one of the outer peripheral surface and the inner peripheral surface of the coil case. In the reactor (claim 1).

Another aspect of the present invention is a method for manufacturing a reactor,
A storage step of storing a viscous magnetic powder mixed resin in which a magnetic powder is mixed with an insulating resin in a storage case;
An insertion step of inserting a cylindrical insert having an electromagnetic coil wound with a conductive wire into the magnetic powder mixed resin;
A solidification step of solidifying the magnetic powder mixed resin to form a core in this order,
At least one of the outer peripheral surface and the inner peripheral surface of the insert is formed with a spiral groove centered on the axis of the insert,
In the inserting step, the insert is inserted into the magnetic powder mixed resin while being rotated around the axis from the end face of the insert (Claim 4 ).

  In the reactor and the manufacturing method thereof, a spiral groove is formed in the cylindrical insert having an electromagnetic coil. Therefore, the insert can be screwed like a screw by inserting the insert (electromagnetic coil) into the magnetic powder mixed resin while rotating around the axis. That is, the helical groove can convert the force for rotating the insert into a force propelled in the axial direction, so that the insert can be inserted into the magnetic powder mixed resin with a small force. Therefore, the load applied to the insert (electromagnetic coil) can be reduced, and the insert can be inserted in a short time.

  As described above, according to the present invention, it is possible to provide a reactor in which an electromagnetic coil can be inserted into a magnetic powder mixed resin in a short time and the load applied to the electromagnetic coil can be reduced, and a manufacturing method thereof.

It is sectional drawing of the reactor in the reference example 1, Comprising: It is BB sectional drawing of FIG. AA sectional drawing of FIG. The manufacturing method explanatory drawing of the reactor in the reference example 1. FIG. The longitudinal cross-sectional view of the reactor in the reference example 1. FIG. The longitudinal cross-sectional view of the reactor in the reference example 2. FIG. It is sectional drawing of the reactor in Example 1 , Comprising: DD sectional drawing of FIG. CC sectional drawing of FIG. The longitudinal cross-sectional view of the reactor in Example 1. FIG. The cross-sectional view of the reactor in Example 2. FIG. The manufacturing method explanatory drawing of the reactor in Example 3. FIG. The manufacturing method explanatory drawing of the reactor in a prior art example. Explanatory drawing of the manufacturing method of the reactor in the prior art example different from FIG.

  The said insertion body can be comprised only from an electromagnetic coil. Moreover, what inserted the whole electromagnetic coil in the coil case can be used as an insertion body, and what covered a part of electromagnetic coil with the other member can be used as an insertion body.

  The reactor can be used for a power conversion device such as an inverter mounted on an electric vehicle or a hybrid vehicle.

Further, the electromagnetic coil has a plurality of cylindrical conductor layers wound with the conductor, the plurality of conductor layers being concentrically arranged around the axis, and the outermost layer among the plurality of conductor layers. and at least one of the innermost layer, the conductor with a predetermined distance Yes spirally wound, it is preferred that the interval is in the above groove (claim 5).
In this case, the groove can be formed in the electromagnetic coil itself. Therefore, an insert can be comprised only with an electromagnetic coil, and the number of parts which comprise an insert can be decreased. Thereby, it becomes possible to reduce the manufacturing cost of a reactor.

Further, the insert body includes a said electromagnetic coil, and a coil case for accommodating said electromagnetic coil, that has the groove is formed on at least one of the above outer peripheral surface and the inner peripheral surface of the coil case.
Therefore , since the electromagnetic coil is housed in the coil case, the load applied to the electromagnetic coil when inserting the electromagnetic coil (insert) into the magnetic powder mixed resin can be further reduced.

Further, two groove portions of a right-handed spiral groove portion that forms a right-handed spiral and a left-handed spiral groove portion that forms a left-handed spiral intersect each other on at least one of the outer peripheral surface and the inner peripheral surface of the coil case. It is preferable to be formed as described above (Claims 2 and 7 ).
In this case, when inserting the insert into the magnetic powder mixed resin, the insert can be rotated in either the right direction or the left direction. It is also possible to insert the insert while alternately changing the rotation in the right direction and the rotation in the left direction. Therefore, the freedom degree of insertion work can be raised.

Moreover, it is preferable that the said groove part is formed in the said outer peripheral surface and the said inner peripheral surface of the said insertion body, respectively (Claim 3 , Claim 8 ).
In this case, since the area in which the groove is formed is large, the force for rotating the insert can be efficiently converted into the force for propelling in the axial direction in the insertion step. Therefore, the insert can be inserted into the magnetic powder mixed resin with a smaller force.

Further, in the insertion step of the manufacturing method of the reactor, it is preferable that while vibrating the magnetic powder mixed resin inserting the insert into the magnetic powder mixed resin (claim 9).
In this case, the insert can be inserted into the magnetic powder mixed resin with a smaller force.

( Reference Example 1)
A reference example relating to the reactor and the manufacturing method thereof will be described with reference to FIGS.
As shown in FIGS. 1 and 2, the reactor 1 of this example includes a storage case 4 and a core 3 stored in the storage case 4. The core 3 is obtained by mixing magnetic powder with insulating resin. A cylindrical insert 10 is inserted into the core 3. The insert 10 of this example is composed of a cylindrical electromagnetic coil 2 around which a conducting wire 20 is wound.
On the outer peripheral surface 12 of the insert 10, a spiral groove 6 centered on the axis a of the insert 10 is formed.

The reactor of this example is used for power converters, such as an inverter and a DC-DC converter, which are mounted on an electric vehicle or a hybrid vehicle.
In this example, iron powder is used as the magnetic powder. The insulating resin is a thermosetting resin such as an epoxy resin.

  As shown in FIGS. 2 and 4, the electromagnetic coil 2 of this example is formed in a cylindrical shape. The electromagnetic coil 2 includes a plurality of cylindrical conductive wire layers 21 (21a to 21d) around which the conductive wire 20 is wound. The conducting wire 20 is a coated conducting wire in which the surface of a metal wire is covered with an insulating film. The several conducting wire layer 21 is arrange | positioned concentrically centering on the axis line a. The plurality of conductive wire layers 21 are composed of a single conductive wire 20. As shown in FIG. 4, the number of turns of the outermost layer 21d among the plurality of conductor layers 21a to 21d is less than the number of turns of the other conductor layer 21c adjacent to the inside of the outermost layer 21d, and is about half. In the outermost layer 21d, the conducting wire 20 is spirally wound with a predetermined interval s (an interval s equal to the diameter of the conducting wire 20). This interval s is a groove 6. In the wiring layers 21 (21a to 21c) other than the outermost layer 21d, the conductive wires 20 are closely packed and wound.

  As shown in FIG. 4, the axis a of the electromagnetic coil 2 is orthogonal to the surface 35 of the core 3. Further, both ends 25 and 26 of the conducting wire 20 protrude from the surface 35 of the core 3 to the outside of the core 3. Both ends 25 and 26 are the electrodes of the reactor 1.

  As shown in FIGS. 1 and 2, the housing case 4 of this example includes a bottom wall 41 and side walls 42 erected from the bottom wall 41 in the Z direction. The side wall 42 is formed in a cylindrical shape. An opening 40 is formed at the end of the housing case 4 opposite to the side provided with the bottom wall 41 in the Z direction.

Next, the manufacturing method of the reactor 1 of this example is demonstrated using FIG. In this example, the reactor 1 is manufactured by performing the storage process mentioned later, an insertion process, and a solidification process in this order.
In the storage step, the magnetic powder mixed resin 30 is stored in the storage case 4. In other words, the magnetic powder mixed resin 30 having viscosity is formed in the housing case 4 by mixing and mixing the magnetic powder and the insulating resin in the housing case 4. As described above, the magnetic powder is, for example, iron powder, and the insulating resin is a thermosetting resin such as an epoxy resin. The viscosity of the magnetic powder mixed resin 30 is, for example, 5 to 200 Pa · s.

  In the insertion step, the insert 10 (electromagnetic coil 2) is put into the case through the opening 40 of the housing case 4 and inserted into the magnetic powder mixed resin 30. At this time, the insert 10 is inserted into the magnetic powder mixed resin 30 while rotating around the axis from the end surface 13 opposite to the side where the both ends 25 and 26 are provided in the axial direction (Z direction).

  In the solidification step, the thermosetting resin contained in the magnetic powder mixed resin 30 is solidified by applying heat. Thereby, the core 3 is formed.

  The effect of this example will be described. In this example, as shown in FIG. 3, a spiral groove 6 is formed in a cylindrical insert 10 (electromagnetic coil 2). Therefore, the insert 10 can be screwed like a screw by inserting the insert 10 (electromagnetic coil 2) into the magnetic powder mixed resin 30 while rotating around the axis a. That is, since the spiral groove 6 can convert the force for rotating the insert 10 into a force propelled in the axial direction (Z direction), the insert 10 can be inserted into the magnetic powder mixed resin 30 with a small force. become. Therefore, the load applied to the insert 10 (the electromagnetic coil 2) can be reduced, and the insert 10 can be inserted in a short time.

Moreover, as shown in FIG. 4, in this example, among the several conducting wire layers 21a-21d which comprise the electromagnetic coil 2, the conducting wire 20 is helically wound in the outermost layer 21b at predetermined intervals s. . This interval s is a groove 6.
If it does in this way, the groove part 6 can be formed in the electromagnetic coil 2 itself. Therefore, the insertion body 10 can be configured only by the electromagnetic coil 2, and the number of parts constituting the insertion body 10 can be reduced. Thereby, the manufacturing cost of the reactor 1 can be reduced.

  As described above, according to this example, it is possible to provide a reactor that can insert the electromagnetic coil into the magnetic powder mixed resin in a short time and reduce the load applied to the electromagnetic coil, and a manufacturing method thereof.

  In addition, in this example, although the helical groove part 6 was formed in the outer peripheral surface 12 of the insertion body 10 (electromagnetic coil 2), you may form the groove part 6 in the internal peripheral surface 11 (refer FIG. 2, FIG. 4). .

  In this example, the magnetic powder mixed resin 30 and the housing case 4 are stationary when the insert 10 is inserted, but the insert is inserted while the magnetic powder mixed resin 30 and the housing case 4 are vibrated. Also good. If it does in this way, it will become easy to insert the insertion body 10 with the magnetic powder mixed resin 30.

( Reference Example 2)
In this example, as shown in FIG. 5, spiral grooves 6 are formed on the outer peripheral surface 12 and the inner peripheral surface 11 of the insert 10 (electromagnetic coil 2), respectively. In this example, similarly to Reference Example 1, a plurality of cylindrical conductive wire layers 21 around which the conductive wires 20 are wound are provided. The plurality of conductive wire layers 21 (21a to 21d) are arranged concentrically around the axis a of the insert 10. In addition, the number of turns of the outermost layer 21d and the innermost layer 21a among the plurality of conductor layers 21 is less than the number of turns of the other conductor layers 21b and 21c adjacent in the radial direction, and is approximately halved. In the outermost layer 21d and the innermost layer 21a, the conducting wire 20 is spirally wound with a predetermined interval s (an interval s equal to the diameter of the conducting wire 20). This interval s is a groove 6.
In addition, the same configuration as the reference example 1 is provided.

The effect of this example will be described. In this example, since the area in which the groove part 6 is formed is large, in the said insertion process, the force which rotates the insertion body 10 can be efficiently converted into the force which propels it to an axial direction (Z direction). Therefore, the insert 10 can be inserted into the magnetic powder mixed resin 30 with a smaller force.
In addition, the same effects as those of Reference Example 1 are obtained.

(Example 1 )
In this example, the configuration of the insert 10 is changed. As shown in FIGS. 6 to 8, in this example, the electromagnetic coil 2 is accommodated in the coil case 5. The insert 10 according to this example includes an electromagnetic coil 2 and a coil case 5.

  The coil case 5 is formed in a cylindrical shape, and the cylindrical electromagnetic coil 2 is accommodated in the coil case 5. On the outer peripheral surface 12 of the coil case 5, a spiral groove 6 centered on the axis a of the insert 10 is formed.

  As shown in FIG. 6, a plurality of protrusions 50 are formed on the outer peripheral surface 12 of the coil case 5. Each protrusion 50 has a parallelogram shape, and has a pair of long sides 51 and 52 parallel to each other, and a pair of short sides 53 and 54. The plurality of protrusions 50 are arranged in parallel to each other. A gap s sandwiched between the long sides 51 and 52 between the two adjacent protrusions 50 is the spiral groove 6 described above.

  A plurality of vertical groove portions 7 parallel to the axial direction (Z direction) of the insert 10 are formed on the outer peripheral surface 12 of the coil case 5. A gap d sandwiched between the short sides 53 and 54 between the two adjacent protrusions 50 is the vertical groove portion 7.

  As shown in FIG. 8, the coil case 5 includes a bottom portion 501 and an opening 55 that opens in the Z direction. From the opening 55, both ends 25 and 26 of the electromagnetic coil 2 protrude outside the coil case 5.

When manufacturing the reactor 1 of this example, first, the magnetic powder and the insulating resin are put in the housing case 4 and mixed to form a viscous magnetic powder mixed resin 30 (storage process). Thereafter, the insert 10 in which the electromagnetic coil 2 is housed in the coil case 5 is inserted into the magnetic powder mixed resin 30 from the bottom 501 side of the coil case 5. At this time, the insert 10 is inserted into the magnetic powder mixed resin 30 while being rotated around the axis a (insertion step). After the insertion is completed, heat is applied to solidify the magnetic powder mixed resin 30 to form the core 3 (solidification step).
In addition, the same configuration as the reference example 1 is provided.

  The effect of this example will be described. As shown in FIGS. 6 to 8, in this example, the electromagnetic coil 2 is housed in the coil case 5, and therefore, when the insert 10 (electromagnetic coil 2) is inserted into the magnetic powder mixed resin 30, it is added to the electromagnetic coil 2. The load can be further reduced.

Moreover, as shown in FIG. 6, the coil case 5 of this example has a plurality of vertical grooves 7 parallel to the Z direction. In this case, for example, when the insert 10 is inserted while the magnetic powder mixed resin 30 is vibrated in the Z direction, a part of the magnetic powder mixed resin 30 passes through the vertical groove 7, so that the resistance during insertion is further increased. Get smaller. Therefore, the insert 10 can be inserted with a smaller force, and the time required for the insertion can be further shortened.
In addition, the same effects as those of Reference Example 1 are obtained.

  In addition, although the groove part 6 was formed in the outer peripheral surface 12 of the coil case 5 in this example, you may form the groove part 6 in the inner peripheral surface 11 (refer FIG. 7, FIG. 8) of the coil case 5. FIG.

(Example 2 )
In this example, the shape of the coil case 5 is changed. As shown in FIG. 9, in this example, groove portions 6 are formed on the outer peripheral surface 12 and the inner peripheral surface 11 of the coil case 5, respectively.
In this case, since the area in which the groove 6 is formed is large, when inserting the insert 10 into the magnetic powder mixed resin 30, the force for rotating the insert 10 is propelled in the axial direction (Z direction). Can be efficiently converted into force. Therefore, the insert 10 can be inserted into the magnetic powder mixed resin 30 with a smaller force.
In addition, the configuration and operational effects are the same as those of the first embodiment.

(Example 3 )
In this example, the shape of the coil case 5 is changed. As shown in FIG. 10, in this example, two groove portions 6, a right-handed spiral groove portion 6 a that forms a right-handed spiral and a left-handed groove portion 6 b that forms a left-handed spiral, intersect each other on the outer peripheral surface 12 of the coil case 5. It is formed to do. A plurality of rhombus-shaped protrusions 50 are formed on the outer peripheral surface 12 of the coil case 5. The plurality of protrusions 50 are parallel to each other. Of the four sides 56 to 59 of the protrusion 50, the first side 56 and the second side 57 are parallel to each other, and the third side 58 and the fourth side 59 are parallel to each other. A gap between two adjacent protrusions 50 sandwiched between the first side 56 and the second side 57 is a right-handed groove portion 6a. Moreover, the space | interval pinched | interposed into the 3rd side 58 and the 4th side 59 of the two adjacent protrusions 50 is the left-handed groove part 6b.

The coil case 5 is formed in a cylindrical shape as in the first embodiment, and includes a bottom 501 and an opening 55. The electromagnetic coil 2 is accommodated in the coil case 5 through the opening 55 to constitute the insert 10.

When manufacturing the reactor 1 of this example, first, the magnetic powder and the insulating resin are put in the housing case 4 and mixed to form the magnetic powder mixed resin 30 (storage process). Thereafter, the insert 10 is inserted into the magnetic powder mixed resin 30 while rotating clockwise or counterclockwise around the axis a (insertion step). Alternatively, the insert 10 is inserted while alternately changing the right rotation and the left rotation. After the insertion, heat is applied to solidify the magnetic powder mixed resin 30 to form the core 3 (solidification step).
In addition, the same configuration as that of the first embodiment is provided.

The effect of this example will be described. In this example, as shown in FIG. 10, two groove portions 6 of the right-handed groove portion 6a and the left-handed groove portion 6b are formed on the outer peripheral surface 12 of the insert 10 (coil case 5) so as to cross each other. is there.
If it does in this way, when performing an insertion process, insert 10 can be rotated to either right rotation or left rotation. Further, the insert 10 can be inserted while alternately changing the right rotation and the left rotation. Therefore, the freedom degree at the time of performing an insertion process can be raised.
In addition, the same effects as those of the first embodiment are obtained.

DESCRIPTION OF SYMBOLS 1 Reactor 10 Insert 2 Electromagnetic coil 20 Conductor 3 Core 30 Magnetic powder mixed resin 4 Storage case 5 Coil case 6 Groove part

Claims (9)

A core in which magnetic powder is mixed with insulating resin;
A cylindrical insert having a cylindrical electromagnetic coil wound with a conducting wire, inserted into the core, and
A housing case for housing the core and the insert,
At least one of the outer peripheral surface and the inner peripheral surface of the insert is formed with a spiral groove centered on the axis of the insert ,
The insert includes the electromagnetic coil and a coil case that houses the electromagnetic coil, and the groove is formed in at least one of the outer peripheral surface and the inner peripheral surface of the coil case. Reactor to do. 2. The reactor according to claim 1 , wherein at least one of the outer peripheral surface and the inner peripheral surface of the coil case includes a right-handed groove portion that forms a right-handed spiral and a left-handed groove portion that forms a left-handed spiral. The reactor is characterized in that the groove portions are formed so as to cross each other. 3. The reactor according to claim 1, wherein the groove is formed on each of the outer peripheral surface and the inner peripheral surface of the insert. A reactor manufacturing method comprising:
A storage step of storing a viscous magnetic powder mixed resin in which a magnetic powder is mixed with an insulating resin in a storage case;
An insertion step of inserting a cylindrical insert having an electromagnetic coil wound with a conductive wire into the magnetic powder mixed resin;
A solidification step of solidifying the magnetic powder mixed resin to form a core in this order,
At least one of the outer peripheral surface and the inner peripheral surface of the insert is formed with a spiral groove centered on the axis of the insert,
In the inserting step, the insert is inserted into the magnetic powder mixed resin while being rotated around the axis from the end face of the insert. 5. The reactor manufacturing method according to claim 4 , wherein the electromagnetic coil has a plurality of cylindrical conductor layers wound with the conductor, and the plurality of conductor layers are concentrically arranged around the axis. The conductive wire is spirally wound at a predetermined interval in at least one of the outermost layer and the innermost layer among the plurality of conductive wire layers, and the interval serves as the groove portion. Reactor manufacturing method. 5. The method for manufacturing a reactor according to claim 4 , wherein the insert includes the electromagnetic coil and a coil case that houses the electromagnetic coil, and at least one of the outer peripheral surface and the inner peripheral surface of the coil case. The above-mentioned groove is formed in the reactor. 7. The method for manufacturing a reactor according to claim 6 , wherein a right-handed spiral groove portion that forms a right-handed spiral and a left-handed spiral groove portion that forms a left-handed spiral are formed on at least one of the outer peripheral surface and the inner peripheral surface of the coil case. The two groove portions are formed so as to cross each other. The reactor manufacturing method according to any one of claims 4 to 7 , wherein the groove is formed on each of the outer peripheral surface and the inner peripheral surface of the insert. Manufacturing method. The method for manufacturing a reactor according to any one of claims 4 to 8 , wherein, in the inserting step, the insert is inserted into the magnetic powder mixed resin while the magnetic powder mixed resin is vibrated. A method for manufacturing a reactor.

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