JP5951941B2 - Coil device and coil - Google Patents

Description

  The present invention relates to a coil device housed in a case, and a coil suitable for the coil device.

  Large-capacity coil devices (for example, reactors) used in hybrid vehicle and electric vehicle drive systems generate a lot of heat due to iron loss and copper loss at high loads, and continue to use the generated heat without releasing it to the outside. Then, the core and the coil are overheated and the electromagnetic characteristics are deteriorated. Therefore, such a coil device is accommodated in a heat radiating case formed of a metal having good thermal conductivity such as an aluminum alloy, and the heat generated by the coil device is released to the outside through the heat radiating case.

  Patent Document 1 discloses an example of a conventional reactor used in a hybrid vehicle. In an automobile reactor, a rectangular coil whose cross section is wound in a substantially rectangular shape is generally used for miniaturization. In addition, in order to ensure electrical insulation and heat conduction between the coil and the heat radiating case, a narrow gap is provided between the coil and the heat radiating case, and this gap is filled with an electrically insulating sealant. .

  In addition, since a large number of automobile reactors are produced, the heat dissipation case is formed by die casting with excellent mass productivity. FIG. 6 shows a cross-sectional view of a conventional reactor 1 ′ that uses a die-cast heat radiating case 50. As shown in FIG. 6, the inner wall surfaces 54 a of the pair of side walls 54 of the heat radiating case 50 form an obtuse angle with the bottom portion 53. That is, the two inner wall surfaces 54a are inclined with respect to each other so that the distance between the inner wall surfaces 54a becomes wider toward the opening side (the upper end side in FIG. 6) of the heat dissipation case 50. Since the metal mold | die which shape | molds the inner wall face 54a of the thermal radiation case 50 also has the same shape, it becomes easy to remove a metal mold | die from the thermal radiation case 50 after die-casting.

  On the other hand, the coil 10 ′ of the reactor 1 ′ is bent at right angles at four locations per turn and has a substantially rectangular cross-sectional shape. The ring core 20 has a substantially rectangular cross section, and the inner peripheral surface of the opposing coil 10 ′ and the outer peripheral surface of the ring core 20 are configured to be parallel to each other.

JP 2009-99596 A

  Due to the above configuration, in the reactor 1 ′, the inner wall surface 54 a of the side wall 54 of the heat radiating case 50 and the side portions 12 a 1 ′ and 12 b 1 ′ of the coil 10 ′ are inclined to each other, and the opening side of the heat radiating case 50 (in FIG. The gap between the side portion 12a of the coil 10 ′ and the inner wall surface 54a of the heat radiating case 50 becomes wider toward the upper end side. Therefore, there is a demerit that heat is difficult to move from the coil 10 ′ to the heat radiating case 50, heat is accumulated on the upper part of the coil 10 ′, the temperature is increased, and the performance of the reactor 1 ′ is deteriorated.

  A coil device according to an embodiment of the present invention is a coil device in which one or more square coils wound so that a cross section thereof is a substantially square shape are housed in a case, the case including a bottom portion, A pair of wall portions that stand up and face each other, and the inner wall surfaces of the pair of wall portions form an angle such that the distance between the wall portions increases as the distance from the bottom portion increases. A wall having a lower part arranged substantially in parallel and a pair of side parts bent up from the lower part, and at least one of the side parts of one or more square coils facing the wall part of the case is opposed to each other It is the coil apparatus arrange | positioned substantially parallel to the inner wall surface of a part. For example, at least one of the inner wall surfaces of the pair of wall portions of the case forms an obtuse angle with the inner bottom surface of the bottom portion, and the side portion facing the inner wall surface forming the obtuse angle with the inner bottom surface is disposed substantially parallel to the inner wall surface. It is good also as a structure. The coil device is, for example, a reactor or a transformer.

  According to the said structure, the fall of the heat dissipation from a coil to a case wall part which arises when using the case which inclined the inner wall face with favorable mold release property at the time of die-casting is prevented.

  The side part of one or more square coils that faces the pair of wall parts of the case may be arranged in parallel with the inner wall surface of the wall part.

  According to this structure, the heat dissipation from a coil to a case wall part further improves.

  The inner wall surfaces of the pair of wall portions of the case may each form an obtuse angle with the inner bottom surface of the bottom portion.

  According to this configuration, it is possible to obtain better case releasability while preventing a decrease in heat dissipation.

  A plurality of square coils arranged in a row so that the side portions face each other may be provided, and the side portions facing the other square coils may be bent at a substantially right angle with respect to the lower portion.

  According to this configuration, since the opposing side portions of the adjacent square coils are parallel to each other, the entire gap between the adjacent square coils can be minimized. Thereby, the heat transfer between the square coils can be improved and the coil device can be made compact. In addition, when a general core having a substantially rectangular cross section is used, the side portion is parallel to the opposite side surface of the core, so that the gap between the core and the coil can be set narrow. As a result, the heat transfer from the core to the coil can be improved and the coil device can be made more compact.

  It is good also as a structure which further has an upper part parallel to a lower part while a square coil connects a pair of side part.

  According to this configuration, when a general core having a substantially rectangular cross section is used, the upper portion of the square coil is parallel to the upper surface of the opposing core, so that the gap between the core and the coil is narrowed. Can be set. As a result, the heat transfer from the core to the coil can be improved and the coil device can be lowered in height.

  A plurality of square coils arranged in parallel to each other may be provided, and the plurality of square coils may be connected in series to form a connection coil.

  According to this configuration, the square coil is folded and accommodated in the case, and a compact coil device with a small length is realized.

  The square coil may be configured as an edgewise coil in which one of the narrow surfaces of the flat wire is wound inward.

  According to this configuration, a coil device having a high cross-sectional area density of the coil, low loss, and good heat dissipation is realized.

  A coil according to an embodiment of the present invention is a square coil suitable for a reactor or a transformer, which is wound so that a cross section thereof is a substantially square shape. The square coil is bent from a lower part and a lower part. And the pair of side parts form an angle such that the distance between the pair of side parts increases as the distance from the lower part increases. For example, at least one of the pair of side portions may have an obtuse angle with the lower portion. Alternatively, one of the pair of side portions may form an obtuse angle with the lower portion, and the other may form a right angle with the lower portion. Moreover, it is good also as a structure where both a pair of side part makes an obtuse angle with a lower part.

  According to this configuration, when housed in a case excellent in releasability at the time of die casting, that is, a case formed so that the inner wall surface and the inner bottom surface of the case form an obtuse angle, it faces the side portion of the square coil. Since the inner wall surface of the case can be made parallel to each other and the distance between the two can be set narrower, a reduction in heat dissipation from the square coil to the case can be prevented and the size of the coil device can be reduced. Is possible.

  According to the configuration of the embodiment of the present invention, it is possible to prevent a decrease in heat dissipation that occurs when a case having an inclined inner wall surface with good releasability at the time of die casting is used.

1 is a perspective view of a reactor according to a first embodiment of the present invention. It is an exploded view of the reactor which concerns on the 1st Embodiment of this invention. It is a cross-sectional view of the reactor which concerns on the 1st Embodiment of this invention. It is a cross-sectional view of the reactor which concerns on the 2nd Embodiment of this invention. It is a cross-sectional view of the reactor which concerns on the 3rd Embodiment of this invention. It is a cross-sectional view of a conventional reactor.

  Hereinafter, the reactor 1 which concerns on the 1st Embodiment of this invention is demonstrated, referring drawings. FIG. 1 is a perspective view of a reactor 1, and FIG. 2 is an exploded view thereof. In the following description, the direction from the lower left side to the upper right side in FIG. 1 is the depth direction (X axis positive direction), the direction from the lower right side to the upper left side is the width direction (Y axis positive direction), and the lower side to the upper side. The direction to go is defined as the height direction (Z-axis positive direction). In addition, when using the reactor 1, you may arrange | position the reactor 1 toward what direction. In the following description, a coil having a substantially rectangular cross section formed by bending at four locations per turn is defined as a square coil.

  As shown in FIGS. 1 and 2, the reactor 1 includes a coil 10, a core module 20, a pair of core fixtures 30, a heat radiating case 50, and a terminal block 60. The reactor body 1 a is configured by the coil 10 and the core module 20. A pair of brackets 21b for attaching the core fixture 30 are formed at both ends in the X-axis direction of the reactor main body 1a (specifically, the core module 20). A nut (attached) is embedded in the bracket 21b by insert molding. The two bolts 72 are passed through a pair of through holes provided in each core fixture 30 and screwed into a female screw of a nut embedded in the pair of brackets 21b so that each core fixture 30 is core module 20. Is attached.

  As shown in FIG. 2, the core module 20 has two U-shaped U-shaped core units 20a and 20b formed in a U-shape, but the U-shaped tips are abutted with each other via a gap member 20g, and an adhesive is used. It is a substantially O-shaped ring core formed by bonding. The core module 20 includes a pair of linear core portions 22a and 22b arranged in parallel, and a pair of connecting core portions 21 that connect both ends thereof. Each of the U-shaped core units 20a and 20b is obtained by coating a U-shaped core formed of a magnetic material with a resin by injection molding (insert molding). In this resin coating, an insulating bobbin conventionally used to electrically insulate a core and a coil is formed integrally with the core, and a resin having electrical insulation and heat resistance (for example, polyphenylene sulfide (PPS )). Moreover, in this embodiment, although the core of a laminated silicon steel plate is used, you may use a powder magnetic core and a ferrite magnetic core. The gap member 20g is a plate material of a non-magnetic material (for example, ceramic such as alumina or resin) having a predetermined thickness.

  The coil 10 includes two linear coil portions 12a and 12b, which are two linear angular coils having the same structure, which are edgewise wound with a rectangular enamel wire, arranged in parallel, and one end (upper right end in FIG. 2) is connected to each other by a connecting portion 14. It has the structure. The linear core portions 22a and 22b of the U-shaped core unit 20a are inserted into the hollow portions of the linear coil portions 12a and 12b from one end side, and the linear core portions 22a and 22b of the U-shaped core unit 20b are inserted from the other end side, respectively. When both end surfaces (gap surfaces 22f) of the U-shaped core units 20a and 20b are abutted and bonded to each other through the gap member 20g, the reactor main body 1a is formed. As shown in FIG. 2, flange portions 20 f are respectively formed at the boundary portions between the straight core portions 22 a and 22 b and the connecting core portion 21 of the U-shaped core units 20 a and 20 b. The coil 10 is sandwiched between the flange portions 20f of the U-shaped core units 20a and 20b and positioned so as not to move in the X-axis direction.

  The heat radiating case 50 is a substantially box-shaped member made of a light metal (for example, an aluminum alloy) with good thermal conductivity and accommodates the reactor body 1a. A mounting seat 52 having a female screw 52f and a positioning pin 52p for mounting the core fixing tool 30 is formed inside both ends of the heat radiating case 50 in the X-axis direction. The reactor main body 1a to which the core fixing tool 30 is attached is housed in the heat radiating case 50, and the core fixing tool 30 is fixed to the mounting seat 52 with bolts 74, whereby the reactor main body 1a is fixed in the heat radiating case 50. At this time, the positioning pin 52p is fitted into the positioning hole 32 provided in the core fixture 30, so that the position of the reactor body 1a with respect to the heat radiating case 50 is accurately adjusted. After the reactor main body 1a is mounted in the heat radiating case 50, a filler (not shown) is filled in the gap between the heat radiating case 50 and the reactor main body 1a. The heat radiating case 50 is installed on the cooling surface of the forced cooling device. That is, the bottom surface 50b of the heat radiating case 50 is in contact with the cooling surface of the forced cooling device, and most of the heat generated in the reactor 1 flows out to the cooling surface of the forced cooling device through the bottom surface 50b of the heat radiating case 50.

  A terminal block 60 is attached to one end of the edge of the heat radiating case 50 with a bolt 76. The terminal block 60 includes bus bars 62a and 62b, and the bus bars 62a and 62b are welded to the lead portions 13a and 13b of the coil 10, respectively.

  As shown in FIG. 2, the heat radiating case 50 includes a rectangular bottom portion 53 having edges parallel to the X axis and the Y axis, and side walls 54 to 56 standing upright from the edges of the bottom portion 53. FIG. 3 is a cross-sectional view of the reactor 1 as viewed in the positive X-axis direction. As shown in FIG. 3, the inner wall surfaces 54 a of the pair of side walls 54 erected from both ends of the bottom portion 53 in the Y-axis direction are in a direction in which the distance increases toward the upper side (Z-axis positive direction side) with respect to the ZX plane. Slightly inclined (for example, 0.5 to 5 °, preferably about 2 °). In addition, the outer wall surface 54b of each side wall 54 is slightly inclined (for example, 0.5 to 5 °, preferably about 1 to 2 °) with respect to the ZX plane in a direction in which the interval becomes narrower toward the upper side. . That is, in the heat dissipation case 50, the thickness of each side wall 54 is thinner toward the upper side. Similarly, the side walls 55 and 56 of the bottom 53 standing upright from both ends in the X-axis direction are inclined such that the inner wall surfaces are opened outward as the upper side and the outer wall surfaces are inclined toward the inner side as the upper side. The thickness of each side wall 55, 56 is thinner toward the upper side. With this configuration, the heat radiating case 50 can be easily removed from the mold after being molded by die casting. Note that as the inclination angle of the inner wall surface 54a and the outer wall surface 54b is set larger, the releasability is improved, but the outer dimensions of the reactor are increased. The inclination angle is determined based on the balance between the outer dimensions and ease of processing (releasability). In addition, the inclination angles of the inner wall surface 54a and the outer wall surface 54b of the side wall 54 can be set to different values depending on the location.

  Further, the side portions 12a1 and 12b1 facing the inner wall surface 54a of the side wall 54 of the heat radiating case 50 in the linear coil portions 12a and 12b are arranged in parallel to the inner wall surface 54a. Specifically, the side portions 12a1 and 12b1 of the linear coil portions 12a and 12b are bent at a slightly obtuse angle (for example, 90.5 to 95 °, preferably 92 °) with respect to the lower portions 12a2 and 12b2. It is bent at a slight acute angle (for example, at 85 to 89.5 °, preferably 88 °) with respect to the upper portions 12a3 and 12b3. With this configuration, the entire distance g between the side portions 12a1 and 12b1 of the linear coil portions 12a and 12b and the side wall 54 of the heat radiating case 50 can be set as small as possible (lower limit value). The heat radiation characteristic to the side wall 54 is optimized.

  The core 20 has a rectangular cross section, and the distance between the core 20 and the side portions 12a1 and 12b1 of the linear coil portions 12a and 12b is wide at the top. Magnetic flux leaking from the gap portion of the core 20 (position where the gap plate 20g is disposed) is one of the causes of copper loss, but the distance between the core 20 (gap portion) and the linear coil portions 12a and 12b is at the top. Since it becomes wide, the effect that a copper loss reduces is acquired.

  Further, various sensors such as a temperature sensor can be arranged in a space S generated between the core 20 and the side portions 12a1 and 12b1 of the linear coil portions 12a and 12b in the upper portion. By arranging the sensor in the space S, the limited space in the reactor 1 can be used effectively.

(Comparative example)
Here, in order to clarify the effect produced by the configuration of the first embodiment, one comparative example (conventional example) is given. FIG. 6 is a cross-sectional view of Comparative Example 1 ′ in which the same heat dissipation case 50 as in the first embodiment and a coil 10 ′ having straight coil portions 12a ′ and 12b ′ formed by bending a flat enamel wire at a right angle are combined. FIG. Since the configuration of Comparative Example 1 ′ excluding the coil 10 ′ is common to the first embodiment, detailed description thereof is omitted. In Comparative Example 1 ′, the inner wall surface 54a of the side wall 54 of the heat radiating case 50 is inclined with respect to the side portions 12a1 ′ and 12b1 ′ of the linear coil portions 12a ′ and 12b ′, and the gap g ′ between the two becomes wider toward the upper side. ing. Accordingly, since the interval g ′ of the comparative example 1 ′ is larger than the lower limit value except for the lower end portion, the moving speed of heat from the coil 10 ′ to the side wall 54 of the heat radiating case 50 is reduced, and therefore the first of the present invention. Compared with the reactor 1 which concerns on this embodiment, heat dissipation becomes low. In particular, in a tall design (long in the Z-axis direction), the gap g ′ is extremely wide at the top, and the heat transfer from the coil 10 ′ to the side wall 54 of the heat radiating case 50 is significantly hindered.

(Second Embodiment)
The first embodiment is an example in which the present invention is applied to a coil device including two linear coil portions, but the present invention is also applied to a coil device including one or three or more linear coil portions. be able to. FIG. 4 is a cross-sectional view of the reactor 100 according to the second embodiment of the present invention including the coil 110 having only one linear coil portion 112. The inner wall surface 154a of each side wall 154 of the heat dissipation case 150 is inclined so as to form a slightly obtuse angle (for example, about 90.5 to 95 °, preferably about 92 °) with the bottom 153. Further, the outer wall surface 154b of each side wall 154 is inclined so as to form a slight acute angle (for example, about 85 to 89.5 °, preferably about 88 to 89 °) with the bottom 153. With this configuration, in the heat dissipation case 150, the thickness of each side wall 154 becomes thinner toward the top, and the interval between the inner wall surfaces 154a of the side walls 154 becomes wider toward the top.

  Moreover, each side part 112a, 112b facing the inner wall surface 154a of each side wall 154 of the thermal radiation case 150 in the linear coil part 112 is arrange | positioned in parallel with the inner wall surface 154a. Specifically, each side portion 112a, 112b of the linear coil portion 112 is bent at a slightly obtuse angle (for example, 90.5 to 95 °, preferably 92 °) with respect to the lower portion 112c. Each of them is bent at a slight acute angle (for example, 85 to 89.5 °, preferably 88 °) with respect to the upper portion 112d. With this configuration, it is possible to set the entire gap g between the side portions 112a and 112b of the linear coil portion 112 and the side wall 154 of the heat radiating case 50 to the lower limit, and heat dissipation from the coil 110 to the side wall 154 of the heat radiating case 150. Properties are optimized.

(Third embodiment)
FIG. 5 is a cross-sectional view of a reactor 200 according to the third embodiment of the present invention, which includes three linear coils 212a to 212c. Also in the heat dissipation case 250 of the third embodiment, the inner wall surface 254a of each side wall 254 is inclined so as to form a slight obtuse angle (for example, about 90.5 to 95 °, preferably about 92 °) with the bottom portion 253. . Further, the outer wall surface 254b of each side wall 254 is inclined so as to form a slight acute angle (for example, about 85 to 89.5 °, preferably about 88 to 89 °) with the bottom 253. With this configuration, in the heat dissipation case 250, the thickness of each side wall 254 becomes thinner toward the top, and the interval between the inner wall surfaces 154a of the side walls 254 becomes wider toward the top.

  Further, the side portion 212a1 of the linear coil portion 212a and the side portion 212b1 of the linear coil portion 212b facing the inner wall surface 254a of each side wall 254 of the heat dissipation case 250 are arranged in parallel with the inner wall surface 254a of each side wall 254 of the heat dissipation case 250. Has been. Specifically, the side portion 212a1 of the linear coil portion 212a and the side portion 212b1 of the linear coil portion 212b are slightly obtuse (for example, 90.5 to 95 °, preferably 92 ° to the lower portions 212a2 and 212b2, respectively. ) And is bent at a slight acute angle (eg, 85 to 89.5 °, preferably 88 °) with respect to the upper portions 212a3 and 212b3, respectively. With this configuration, it becomes possible to set the entire interval g between the side portion 212a1 of the linear coil portion 212a and the side portion 212b1 of the linear coil portion 212b and the side wall 254 of the heat radiating case 250 to the lower limit value. The heat dissipation characteristics from 212b to each side wall 254 of the heat dissipation case 250 are optimized.

  The above is the description of the exemplary embodiments of the present invention. Embodiments of the present invention are not limited to those described above, and can be arbitrarily changed within the scope of the technical idea expressed by the description of the scope of claims.

  In the above embodiment, an edgewise coil (edgewise coil) is used in which the edge surface (side surface with a narrow width) of a flat enamel wire is wound toward the central axis (coil axis). It is also possible to apply to a flat wound coil (flat coil) in which the wide side of the coil is wound toward the coil axis. The present invention can also be applied to a square coil in which a round wire is wound so that the cross section is substantially square.

  In the above-described embodiment, the present invention is applied to a coil device including a linear coil. However, the present invention is also applied to a coil device including a toroidal coil in which a square coil is looped in an annular shape (a donut shape). can do.

  Further, in the above embodiment, the side portions of the linear coil that face each side wall of the heat radiating case are formed obliquely so as to be parallel to the inner wall surface of the side wall of the heat radiating case, but face one side wall. Only the side portion of the linear coil may be formed obliquely.

  The above embodiment is an example in which the present invention is applied to a coil device using a core module in which a magnetic core and a bobbin (resin-coated portion) are integrally formed by injection molding. The present invention can also be applied to a configuration using an insulating bobbin made of resin.

  Moreover, although said embodiment is an example which applied this invention to the reactor, this invention is applicable also to another kind of coil apparatus (for example, transformer).

  In the above embodiment, the core has a rectangular cross-sectional shape, but the cross-sectional shape is trapezoidal so that each side surface of the core is parallel to the inner peripheral surface of the opposing coil (that is, It may be formed in a shape substantially similar to the cross-sectional shape of the inner peripheral surface of the coil.

  In the above embodiment, the inner wall surfaces of the opposing side walls of the heat radiating case are inclined so as to form an obtuse angle with the upper surface (XY surface) of the bottom portion, but the distance between the opposing inner wall surfaces increases as the distance from the bottom portion increases. As long as it forms so that the inner wall surface of one side wall may form a right angle or an acute angle with the upper surface of a bottom part.

  Further, in the above embodiment, the coil is formed by bending the conducting wire non-right angle so that the outer peripheral surface of the coil facing the side wall of the heat radiating case is substantially parallel to the inner wall surface of the side wall. Even if the outer peripheral surface of the coil and the inner peripheral surface of the side wall of the heat radiating case are not completely parallel, the lead wire is bent non-right angle so that the angle formed by both is smaller than when the lead wire is bent at a right angle. Even when the coil is formed, the same effect as the above-described embodiment can be obtained.

DESCRIPTION OF SYMBOLS 1 Reactor 1a Reactor main body 10 Coil 20 Core module 30 Core fixing tool 40 Thermistor 50 Radiation case 60 Terminal block

Claims (9)

Case and
One or more square coils wound in such a way that the cross-section is substantially rectangular and housed in the case;
A core having a cross section formed in a substantially rectangular shape and having a portion inserted into the hollow portion of the square coil;
With
The case has a bottom portion and a pair of wall portions standing upright and facing from the bottom portion,
The inner wall surfaces of the pair of wall portions form an angle such that the distance between the inner wall surfaces increases as the distance from the bottom portion increases.
The square coil is
A lower portion disposed substantially parallel to the inner bottom surface of the case;
A pair of side parts that are bent and raised from the lower part, and
At least one side of the one or more square coils facing the wall of the case is
While being arranged substantially parallel to the inner wall surface of the opposing wall portion,
The distance between the opposing cores increases as the distance from the lower part increases.
Coil device. At least one of the inner wall surfaces of the pair of wall portions of the case forms an obtuse angle with the inner bottom surface of the bottom portion;
The coil device according to claim 1, wherein the side portion facing the inner wall surface forming an obtuse angle with the inner bottom surface is disposed substantially parallel to the inner wall surface. The coil device according to claim 2, wherein the inner wall surfaces of the pair of wall portions of the case form an obtuse angle with the inner bottom surface of the bottom portion. The side portions of the one or more square coils facing the pair of wall portions of the case are respectively arranged in parallel with the inner wall surface of the wall portion. The coil apparatus as described in any one of these. A plurality of the square coils arranged in a row so that the side portions are opposed to each other, and the side portions facing the other square coils are bent at a substantially right angle with respect to the lower portion. The coil device according to any one of claims 1 to 4. The coil device according to any one of claims 1 to 5, wherein the square coil further includes an upper portion that connects the pair of side portions and is parallel to the lower portion. 7. The apparatus according to claim 1, further comprising a plurality of the square coils arranged in parallel to each other, wherein the plurality of square coils are connected in series to form a connection coil. 8. Coil device. The coil device according to any one of claims 1 to 7, wherein the square coil is an edgewise coil in which one of narrow surfaces of a flat wire is wound inward. It is a reactor, The coil apparatus as described in any one of Claims 1-8 characterized by the above-mentioned.

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