JPWO2015068265A1 - Electromagnetic induction equipment - Google Patents

Abstract

In the electromagnetic induction device according to the present invention, a coil body composed of a wiring pattern of a printed wiring board and a metal part having both end portions connected to the wiring pattern is electrically connected and overlapped to form a coil body. For example, by attaching a cooling means to the printed wiring board, the coil body can efficiently dissipate heat, and the thermal resistance can be reduced.

Description

  The present invention relates to an electromagnetic induction device incorporated in, for example, a power converter.

Power converters such as DCDC converters and chargers installed in electric and hybrid vehicles are equipped with electromagnetic induction devices such as transformers, reactors, and choke coils as passive components that perform voltage step-up and step-down operations. It is used for energy storage, emission element, or DC current smoothing.
Regarding such an electromagnetic induction device, a structure that can be miniaturized or efficiently dissipate heat generated during energization is very important.

  As a transformer excellent in miniaturization, the primary winding and the secondary winding are configured in a laminated structure, and the secondary winding is separated from the insulating member, and at least two locations in the axial direction of the bobbin surrounding the core What realized the miniaturization by winding in divided is known (for example, refer to patent documents 1).

  Moreover, as a reactor excellent in heat dissipation, the reactor body is housed in an aluminum case, and the reactor body is sealed with a filling resin having a thermal conductivity of 0.7 to 4.0 [W / m / K]. It is known that heat generated from the coil can be efficiently dissipated to the case and the cooler, and further, heat generated from the core can be efficiently dissipated by adopting a bobbinless structure. (For example, refer to Patent Document 2).

JP 2010-183751 A JP 2009-94328 A

  However, in Patent Document 1, the primary winding and the secondary winding are stacked and wound to increase the degree of coupling between the windings. Although it is possible to reduce the size by winding it in two or more locations in the axial direction, since the winding is wound in a multi-layer structure, the inner winding near the core is located outside the winding. There was a problem that heat dissipation deteriorates by adding the thermal resistance of the insulator between the windings.

  Moreover, the thing of the said patent document 2 had the problem that a cost increase and an enlargement would be forced when a reactor main body was accommodated in a metal case and it was filled with thermal radiation resin.

  An object of the present invention is to provide an electromagnetic induction device that is low in cost, small in size, can efficiently dissipate heat from a coil body, and can reduce thermal resistance. The purpose is that.

The electromagnetic induction device according to the present invention is:
A core constituting a closed magnetic circuit;
A printed wiring board supporting the core and having a plurality of wiring patterns;
A metal member that circulates around the core and has both ends connected to the wiring pattern,
A plurality of coil portions made of the wiring pattern and the metal member are electrically connected to each other and overlapped to constitute a coil body.

According to the electromagnetic induction device according to the present invention, a coil body composed of a wiring pattern of a printed wiring board and a coil portion composed of a metal member having both ends connected to the wiring pattern is electrically connected to each other to form a coil body. Therefore, for example, by attaching a cooling means to the printed wiring board, the coil body can efficiently dissipate heat, and the thermal resistance can be reduced.
Moreover, since a metal member is spaced apart and connected to the wiring pattern of a printed wiring board for every metal member, the heat dissipation of each metal member is also high.

It is a perspective view which shows the reactor in Embodiment 1 of this invention. It is a top view which shows the wiring pattern of the printed wiring board of FIG. It is a perspective view which shows the trans | transformer in Embodiment 2 of this invention. It is a top view which shows the wiring pattern of the printed wiring board of FIG. It is a figure which shows an example which showed typically the arrangement | positioning of the primary winding part of a transformer, and a secondary winding part. It is the figure which showed typically arrangement | positioning of the primary winding part of a transformer in Embodiment 3 of this invention, and a secondary winding part.

  Hereinafter, embodiments of the present invention will be described. In the drawings, the same or corresponding members and parts will be described with the same reference numerals.

Embodiment 1 FIG.
1 is a perspective view showing a reactor according to Embodiment 1 of the present invention, and FIG. 2 is a top view showing a wiring pattern 8 on a metal base printed wiring board 6 of FIG. In FIG. 1, a plurality of electronic components mounted on the metal base printed wiring board 6 are omitted.
This reactor, which is an electromagnetic induction device, is installed so as to surround a core 3 that is a PQ core that is an outer iron type and includes a first core portion 1 and a second core portion 2, and a middle leg portion of the core 3. Metal having a plurality of C-shaped plate-like metal members 4 formed, insulating members 5 that insulate the plate-like metal members 4 from each other and the plate-like metal members 4 and the core 3, and a plurality of wiring patterns 8 on the upper surface A base printed wiring board 6.
This reactor is fixed to the cooler by installing and fixing the metal base printed wiring board 6 on a cooler (not shown) as a cooling means.

The plate-like metal member 4 is a tough pitch copper material having a specified electric resistance value.
The wiring pattern 8 of the metal-based printed wiring board 6 is a conductor having a prescribed electric resistance value, and is coated with an insulating resist except for a rectangular component land 7. Each wiring pattern 8 is electrically connected via a connection portion (not shown).
Both end surfaces of each plate-like metal member 4 are in contact with each component land 7 and soldered to form a coil portion composed of the plate-like metal member 4 and the wiring pattern 8. Each of the coil portions is electrically connected to each other, and a coil body is configured by stacking a predetermined number of middle leg portions of the core 3.

  The distance between the component land 7 and the transfer portion of the wiring pattern 8 that connects the adjacent lands 7 and the distance between the adjacent component lands 7, which are the lowest part and the highest part in FIG. The width is such that when a predetermined voltage is applied to the transformer, insulation can be secured against the voltage drop of the coil portion for one turn.

The bottom surface of the core 3 is installed on the metal base printed wiring board 6.
The insulating member 5 includes a half donut portion that is a half of a donut-like plate interposed between adjacent plate-like metal members 4, a cylindrical cylindrical portion that surrounds the middle leg portion of the core 3, and the plate-like metal member 4. The outer diameter side portion interposed between the outer diameter side and the inner wall of the core 3.

In the reactor configured as described above, the metal base printed wiring board 6 on which the coil body is arranged is mounted on the cooler. Therefore, the coil body can efficiently dissipate heat, and heat generated by the temperature rise of the coil body. An increase in resistance can be suppressed.
Moreover, since the heat radiation area can be reduced by reducing the heat radiation area, the core 3, the plate-like metal member 4, the metal base printed wiring board 6 and the like constituting the reactor are reduced in size and weight. , And the associated cost reduction.
It is possible to reduce the size and cost of the cooler that cools the reactor.

  In addition, since the plate-like metal member 4 is a plate-like member, it is possible to stabilize the dimensional accuracy, so that variation in leakage inductance can be suppressed, and loss variation in the coil body can be suppressed.

  Further, the number of coil portions stacked, the plate width of the plate-like metal member 4 that is a component of the coil body, the distance between the coil body and the core 3, and the first core portion 1 and the second core portion 2 By adjusting the gap between them, the inductance can be easily adjusted.

  Further, by connecting the plate-like metal members 4 to the component lands 7 of the metal base printed wiring board 6 one by one, the respective plate-like metal members 4 are arranged apart from each other, and one plate-like metal member 4 is provided. Since heat can be radiated every time, it is possible to reduce thermal resistance and improve heat dissipation.

Furthermore, unlike the reactor described in Japanese Patent Application Laid-Open No. 2009-94328 (Patent Document 2) described above, it is not necessary to store the reactor body in a metal case and fill the heat radiation resin to secure a heat radiation path. Miniaturization, weight reduction, and cost reduction are possible.
Further, since the plate-like metal member 4 is connected to the component land 7 every round, it becomes possible to stabilize the dimensional accuracy between the coil portions which are the constituent elements of the coil body, and the thermal resistance, inductance, and coil body loss. Variation in isoelectric characteristics can be reduced.

In addition, by using a tough pitch copper material for the plate-like metal member 4, electrical conductivity close to that of pure copper can be obtained, and a low electrical resistance can be realized as a coil body. At the same time, since it is a non-magnetic metal, The accompanying eddy current generation and eddy current loss can be reduced.
Moreover, since the loss amount is suppressed and the thermal conductivity is close to that of pure copper, the heat generated from the plate-like metal member 4 can be efficiently radiated through the metal base printed wiring board 6 and the cooler. It becomes possible. In addition, the size and weight can be reduced.

In this embodiment, a copper-based material is used, but the present invention can also be applied to an aluminum-based material. By making the plate-like metal member 4 used for the coil body an aluminum-based material, the heat dissipation and conductivity are inferior to those of the copper-based material, but since it is a non-magnetic metal, the generation of eddy currents can be suppressed. Since specific gravity is extremely small compared with a metal, especially when the number of turns of a coil body increases, it is possible to realize significant weight reduction.
Moreover, since the unit price of the material is significantly lower than that of the copper-based material, the cost can be reduced.

  Further, by placing the bottom surface of the core 3 in contact with the metal base printed wiring board 6, heat loss (iron loss) generated in the core 3 can be radiated to the cooler through the metal base printed wiring board 6.

  Further, by interposing an insulating member 5 such as a resin plate or an insulating sheet between the plate-like metal member 4 and between the plate-like metal member 4 and the adjacent core 3, between each adjacent plate-like metal member 4, Insulation between the coil body and the core 3 is ensured, and the performance as a reactor can be stabilized.

  Moreover, when the insulation distance is ensured between the plate-shaped metal members 4 and between the plate-shaped metal member 4 and the adjacent core 3, the insulation member 5 may not be interposed.

  In this embodiment, the plate-like metal member 4 is used as a component of the coil body. However, a round wire or a rectangular wire may be used instead of the plate-like metal member 4.

  In this embodiment, the metal base printed wiring board 6 which is a component of the coil body has been described. However, instead of the metal base printed wiring board 6, a ceramic base printed wiring board may be used. Under the present circumstances, by using a ceramic base printed wiring board, heat dissipation can also be improved, ensuring high insulation. In addition, downsizing and weight reduction associated therewith can be realized.

  Further, in this embodiment, the core 3 has been described in the case of a PQ type core that is an outer iron type, but other outer iron type cores such as EI, EE, EER, and ER types, and an inner iron such as a U type. The present invention can also be applied to a formula core.

Embodiment 2. FIG.
3 is a perspective view showing a transformer according to Embodiment 2 of the present invention, and FIG. 4 is a top view showing wiring patterns 17 and 19 on the metal base printed wiring board 15 of FIG. In FIG. 3, a plurality of electronic components mounted on the metal base printed wiring board 15 are omitted.
This transformer, which is an electromagnetic induction device, is installed so as to surround a core 11, which is a U-shaped core, composed of a first core portion 9 and a second core portion 10, and one magnetic leg of the core 11. Between the C-shaped metal plate 12 for primary winding and the plate-like metal member 13 for secondary winding, and between the plate-like metal member 12 for primary winding and the plate-like metal member 13 for secondary winding In addition, an insulating member 14 that insulates between the plate-like metal members 12 and 13 and the core 11, and a metal base printed wiring provided with a primary winding wiring pattern 17 and a secondary winding wiring pattern 19 on the upper surface. And a plate 15.
This transformer is fixed to the cooler by installing and fixing the metal base printed wiring board 15 on a cooler (not shown).

The plate metal member 12 for primary winding is a tough pitch copper material having a specified electric resistance value.
The wiring pattern 17 for the primary winding of the metal base printed wiring board 15 has a prescribed electric resistance value and is coated with an insulating resist except for the rectangular primary winding component land 16. Note that the primary winding wiring pattern 17 is electrically connected via a connection portion (not shown).
Both end surfaces of each primary winding plate-like metal member 12 are connected to each primary winding component land 16 by being soldered to each other and connected to the primary winding plate-like metal member 12. A primary winding portion, which is a coil portion, composed of the primary winding wiring pattern 17 is formed.
Each primary winding portion is electrically connected to each other, and a primary winding 20 that is a coil body is configured by stacking a predetermined number of one leg of the core 11.

The plate metal member 13 for secondary winding is a tough pitch copper material having a specified electric resistance value.
The wiring pattern 19 for the secondary winding of the metal-based printed wiring board 15 has a prescribed electric resistance value and is coated with an insulating resist except for the secondary winding component land 18 such as a rectangular shape. . Note that the secondary winding wiring pattern 19 is electrically connected via a connection portion (not shown).
Both end surfaces of each secondary winding plate-like metal member 13 are connected to each secondary winding component land 18 by soldering, and are connected to each other. A secondary winding portion, which is a coil portion, composed of the secondary winding wiring pattern 19 is formed.
The secondary winding portions are electrically connected to each other, and the secondary winding 21 that is a coil body is configured by overlapping one leg of the core 11 by a predetermined number of turns.

In this embodiment, the primary winding of the primary winding wiring pattern 17 is arranged in order to alternately arrange the primary winding plate-like metal members 12 and the secondary winding plate-like metal members 13. As shown in FIG. 4, the line component land 16 and the secondary winding component land 18 of the secondary winding wiring pattern 19 are shifted by a distance of d1 along the axial direction.
Further, in order to secure an insulation distance between the adjacent primary winding wiring pattern 17 and the secondary winding wiring pattern 19, as shown in FIG. .

In the transformer configured as described above, the metal base printed wiring board 15 on which the primary winding 20 and the secondary winding 21 are arranged is mounted on the cooler. Heat radiation of the wire 21 can be performed efficiently, and an increase in thermal resistance due to a temperature rise in the primary winding 20 and the secondary winding 21 can be suppressed.
Further, since the heat radiation area is improved, the heat radiation area of the entire transformer can be reduced. Therefore, the core 11, the primary winding plate metal member 12, and the secondary winding plate metal constituting the transformer. The member 13, the metal base printed wiring board 15 and the like can be reduced in size and weight, and the cost can be reduced accordingly.

  In addition, since the plate metal member 12 for the primary winding and the plate metal member 13 for the secondary winding are plate members, it is possible to stabilize the dimensional accuracy and suppress the variation of the leakage inductance, Loss variation of the primary winding 20 and the secondary winding 21 can be suppressed.

  Further, by alternately arranging the plate-like metal members 12 and the plate-like metal members 13 for the primary winding, a transformer with a high degree of coupling can be realized, and leakage inductance can be suppressed.

  Further, the number of coil portions stacked, the plate width of the primary winding plate metal member 12 and the secondary winding plate metal member 13, and between the primary winding 20 and the secondary winding 21 and the core 11. By adjusting the distance and the gap between the first core part 1 and the second core part 2, adjustment of the excitation inductance and the leakage inductance becomes easy.

In addition, the primary winding plate metal member 12 and the secondary winding plate metal member 13 are connected to the component lands 16 and 18 on the metal base printed wiring board 15 one by one, thereby making the primary winding. Since the plate-like metal member 12 for wires and the plate-like metal member 13 for secondary winding can be dissipated one by one, the thermal resistance can be reduced and the heat dissipation can be improved.
In addition, the primary winding plate metal member 12 and the secondary winding plate metal member 13 are connected to the component lands 16 and 18 every round so that the primary winding 20 and the secondary winding 21 are connected. It is possible to stabilize the dimensional accuracy of the gap between the two, and to reduce variations in electrical characteristics such as thermal resistance and excitation, leakage inductance, and loss.

Moreover, the plate-like metal member 12 for the primary winding and the plate-like metal member 13 for the secondary winding are made of a tough pitch copper material, whereby a conductivity close to that of pure copper is obtained, and the primary winding 20 and the secondary winding. 21 can realize low electrical resistance, and at the same time, since it is a non-magnetic metal, generation of eddy currents accompanying leakage magnetic flux generated from the transformer and eddy current loss can be reduced.
Moreover, since the loss amount is suppressed and the thermal conductivity is close to that of pure copper, the heat generated from the plate metal member 12 for the primary winding and the plate metal member 13 for the secondary winding is efficiently used. In particular, it is possible to dissipate heat through the metal base printed wiring board 15 and the cooler. In addition, the size and weight can be reduced.

Further, between the two plate-like metal members 12 and 13, between the two plate-like metal members 12 and 13 and the core 11 adjacent to both the plate-like metal members 12 and 13, an insulating member 14 such as a resin plate or an insulating sheet is provided. By interposing, insulation between the primary winding 20 and the secondary winding 21, between the two plate-like metal members 12 and 13, and between the primary winding 20, the secondary winding 21 and the core 11 is achieved. It can be ensured and the performance as a transformer can be stabilized.
Also, the assemblability can be improved.
It is also possible to secure insulation by resin-molding the two plate-like metal members 12 and 13 which are constituent elements of the primary winding 20 and the secondary winding 21.

  Further, the primary windings 20 and 2 are provided by providing a distance that can be insulated between the primary winding wiring pattern 17 and the secondary winding wiring pattern 19 with respect to a predetermined voltage applied to the transformer. The insulation between the secondary windings 21 is ensured, and the performance as a transformer can be stabilized.

  In this embodiment, a copper-based material is used for both plate-like metal members 12 and 13, but it can be applied to an aluminum-based material as in the first embodiment.

  In this embodiment, the metal-based printed wiring board 15 is used as the printed wiring board that is a constituent element of the primary winding 20 and the secondary winding 21. However, as in the second embodiment, ceramic is used. It may be a base printed wiring board.

  In this embodiment, the step-up transformer is described as having a higher number of turns of the secondary winding 21 than the primary winding 20, but a step-down transformer having a higher number of turns of the primary winding than the secondary winding. The present invention can also be applied to a transformer.

  Further, in this embodiment, the U-type core in which the core 11 is an inner iron type has been described. However, the present invention can also be applied to an outer iron type core such as an EI, EE, EER, or ER type.

Embodiment 3 FIG.
FIG. 5A is a diagram schematically showing an example of the arrangement of the primary winding portion 20a and the secondary winding portion 21a of the transformer, and FIG. 5B is a primary winding portion 20a of the transformer according to Embodiment 3 of the present invention. It is the figure which showed typically arrangement | positioning of the secondary winding part 21a.
When the transformation ratio of the transformer is large, there are cases where the numbers of the primary winding portion 20a and the secondary winding portion 21a are greatly different. For example, as shown in FIG. 5A, the secondary winding portion 21a is continuous. As a result, the three adjacent to each other occurs, which increases the leakage inductance of the transformer and increases the loss of the transformer.
For this, as shown in FIG. 5B, up to two secondary windings 21a are arranged adjacent to each other to suppress an increase in the leakage inductance of the transformer, to further increase the degree of coupling, and to suppress loss. can do.
Other configurations are the same as those of the transformer of the second embodiment.

In each of the above embodiments, a reactor and a transformer have been described as electromagnetic induction devices. However, a choke coil may be used.
Further, as an example of the cooling means for cooling the electromagnetic induction device, the cooler in which the refrigerant circulates has been described, but a heat sink may be used.

  DESCRIPTION OF SYMBOLS 1 1st core part, 2nd core part, 3,11 core, 4 plate-shaped metal member (metal member), 5,14 insulation member, 6,15 metal base printed wiring board, 7 component land, 8 wiring Pattern, 9 1st core part, 10 2nd core part, 12 Plate metal member (metal member) for primary winding, 13 Plate metal member (metal member) for secondary winding, 16 Primary winding Wire component land, 17 Primary winding wiring pattern, 18 Secondary winding component land, 19 Secondary winding wiring pattern (wiring pattern), 20 Primary winding (coil body), 20a Primary winding Line part (coil part), 21 secondary winding (coil body), 21a secondary winding part (coil part).

Claims (21)

A core constituting a closed magnetic circuit;
A printed wiring board supporting the core and having a plurality of wiring patterns;
A metal member that circulates around the core and has both end portions connected to the wiring pattern, and a plurality of coil portions made of the wiring pattern and the metal member are electrically connected to each other and stacked to form a coil body. Electromagnetic induction equipment.   The electromagnetic induction device according to claim 1, wherein the metal member is a plate-like metal member.   The electromagnetic induction device according to claim 2, wherein an insulating member is interposed between the adjacent plate-like metal members and between the plate-like metal member and the core.   The electromagnetic induction device according to claim 1, wherein the metal member is a round wire.   The electromagnetic induction device according to claim 1, wherein the metal member is a flat wire.   The electromagnetic induction device according to claim 1, wherein the metal member makes one turn around the core.   The electromagnetic induction device according to claim 1, wherein the metal member is connected to the printed wiring board by soldering.   The electromagnetic induction device according to claim 1, wherein the metal member is made of copper.   The electromagnetic induction device according to claim 1, wherein the metal member is made of aluminum.   The electromagnetic induction device according to claim 1, wherein the printed wiring board is a metal-based printed wiring board.   The electromagnetic induction device according to claim 1, wherein the printed wiring board is a ceramic base printed wiring board.   The electromagnetic induction device according to claim 1, wherein the core is in surface contact with the printed wiring board.   The electromagnetic induction device is a transformer, and the coil body is composed of a primary winding composed of a primary winding portion that is the coil portion and a secondary winding portion that is a coil portion. The electromagnetic induction device according to claim 1, wherein the electromagnetic induction device is a next winding.   The electromagnetic induction device according to claim 13, wherein the primary winding portion and the secondary winding portion are alternately stacked.   14. The electromagnetic induction device according to claim 13, wherein up to two of the primary winding portion and the secondary winding portion are adjacent to each other.   The primary winding component land of the wiring pattern to which the primary winding metal member, which is a component of the primary winding portion, is connected, and the secondary winding adjacent to the primary winding component land. The secondary winding component land of the wiring pattern to which the secondary winding metal member, which is a constituent element of the winding portion, is connected and is separated from the secondary winding component land. The electromagnetic induction device according to claim 1.   An insulating member is interposed between the primary winding metal member and the secondary winding metal member, between the primary winding metal member, and between the secondary winding metal member and the core. The electromagnetic induction device according to claim 16, wherein the electromagnetic induction device is interposed.   The electromagnetic induction device according to claim 17, wherein the insulating member is a resin plate.   The electromagnetic induction device according to claim 17, wherein the insulating member is a resin sheet.   The electromagnetic induction device according to claim 17, wherein the metal member for primary winding and the metal member for secondary winding are resin-molded.   The electromagnetic induction device according to any one of claims 1 to 20, wherein a cooling means for cooling the electromagnetic induction device is attached to the printed wiring.

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