KR20160137360A - Reactor device and electricelectronic apparatus - Google Patents

Abstract

Provided is a reactor device which can reduce a possibility that a reactor body is separated from a casing during use and can suppress a reduction in a magnetic characteristic of the reactor device. Also provided is an electric/electronic apparatus having the same. The reactor device (100) comprises: a reactor body (20) which comprises a core (10) configured to have a ring shape when viewed in a plan view and a coil (15) wound around the core (10); a casing (30) which accommodates a reactor body (20); and an encapsulant (40) which fills a gap between the reactor body (20) and the casing (30); wherein the core (10) comprises a compressed powder core including a powder compact formed by compressing and molding a material including a magnetic powder; the core (10) comprises two rectilinear portions (12a, 12b) configured to have portions inserted into the coil (15) and define rectilinear magnetic paths and two curved portions (11a, 11b) configured to be connected to ends of the rectilinear portions (12a, 12b) and define curved magnetic paths; the encapsulant (40) comprises first encapsulants (41a, 41b) located between the curved portions (11a, 11b) and the casing (30) and a second encapsulant (42) located between at least part of the rectilinear portions (12a, 12b) and the casing (30); and Youngs modulus of the first encapsulants (41a, 41b) is lower than Youngs modulus of the second encapsulant (42).

Description

REACTOR DEVICE AND ELECTRONIC APPARATUS BACKGROUND OF THE INVENTION Field of the Invention [0001]

The present invention relates to a reactor apparatus and an electric / electronic apparatus including the reactor apparatus.

BACKGROUND ART [0002] A reactor device used in a booster circuit, a power generation device, and a power generation facility of a hybrid vehicle or the like includes a reactor body made of an annular core and a coil wound on the core, a casing accommodating the reactor body, (For example, refer to Patent Document 1 and Patent Document 2).

When an AC current is applied at the time of use, the reactor is periodically deformed in accordance with a change in AC current due to the magnetostriction characteristic of the core, and vibration or heat is generated from the reactor main body. The sealing member is required to withstand the vibration from the reactor main body and the vibration imparted to the reactor device from the environment (for example, automobile) where the reactor device is placed, and fix the reactor main body to the casing.

Japanese Laid-Open Patent Publication No. 2012-142379 Japanese Patent Application Laid-Open No. 2014-224189

The encapsulating material filled between the reactor main body and the casing is formed by potting (casting) the curable composition between the reactor main body and the casing and curing the curable composition in a state where the reactor main body is housed in the casing as shown in Patent Document 2 do. From the viewpoint of firmly fixing the reactor main body to the casing, it is preferable that the sealing material is made of a hard material, specifically a material having a high Young's modulus. However, the curable composition capable of forming a hard sealing material gives a strong compressive stress to the core of the reactor main body due to volume shrinkage during curing. When the core is subjected to a strong compressive stress, the magnetic properties of the reactor main body, particularly the iron loss, are adversely affected. This tendency becomes conspicuous when the reactor body is provided with a compaction core.

As a method for avoiding such an influence, it is conceivable to use, as a curing composition for forming an encapsulating material, a material which is hard to impart compressive stress to the core at the time of curing. In this case, however, the encapsulation material, which is a hardened product, becomes soft (having a low Young's modulus), and the risk of vibration of the reactor main body or vibration from the reactor device causes the reactor main body to fall off from the casing.

SUMMARY OF THE INVENTION In view of the foregoing, it is an object of the present invention to provide a reactor device capable of reducing the possibility of a problem that the reactor main body falls off from the casing during use, and suppressing deterioration of the magnetic characteristics of the reactor device, And to provide an electric / electronic apparatus equipped therewith.

According to an aspect of the present invention, which is provided to solve the above problems, the present invention provides, in one aspect, a reactor body including an annular core in a plan view and a coil wound around the core, a casing accommodating the reactor main body, And a sealing material filled between the casings, wherein the core is made of a press compaction core comprising a green compact obtained by press-molding a material containing magnetic powder, the core comprising: And two curved portions that are formed continuously and formed on respective end portions of the straight portion so as to divide and form a curved magnetic path, The sealing member includes a first sealing member positioned between the curved portion and the casing, and a second sealing member located between the at least a portion of the straight portion and the casing 2, the encapsulation material and a Young's modulus of the first sealing material is a reactor wherein the first sealing member 2 is lower than the Young's modulus.

The degree of the influence of the compressive stress received by the core of the reactor main body upon the magnetic characteristics of the reactor device when the curable composition for forming the sealing material is hardened and shrunk varies depending on the shape of the core. In the case where the shape of the core is complicated, the degree of influence on the magnetic properties, particularly the iron loss, tends to be larger than in the case where the shape of the core is a relatively simple shape such as a bar shape.

Therefore, in the present invention, in the case of a portion (rectilinear section) for partitioning a straight-line magnetic path, an encapsulating material positioned between the core and the casing, which has an annular shape in plan view so as to form a closed- (A first encapsulation member) for partitioning a non-linearly-shaped and folded magnetic path (a curved portion), and the second encapsulation member is made of a relatively hard material (having a high Young's modulus) The ash is made of relatively soft material (low Young's modulus). Since the second encapsulant is made of a hard material, it is possible to firmly fix the reactor main body to the casing. The curable composition for forming the second encapsulation imparts a large compressive stress to the core due to the curing shrinkage, but since the portion of the core fixed by the second encapsulant is a straight portion, The deterioration of characteristics is not generated well. Since the first encapsulant, which is relatively soft and less affected by the hardening shrinkage, is located between the curved portion having a relatively complicated shape in the core and the casing, deterioration of the magnetic characteristics of the reactor device It does not. The reason for this is that when the same force is applied to the straight portion and the bending portion, the influence of the stress on the core is very large on the side of the bending portion and the deterioration of the magnetic property is also large. The influence of the applied stress is reduced. Therefore, the reactor device according to the present invention does not cause deterioration of the magnetic characteristics of the reactor device due to the curing shrinkage of the curable composition providing the sealing material.

The curable composition for forming an encapsulating material preferably includes a resin-based material for ease of handling and the like. Therefore, it is preferable that the first encapsulant and the second encapsulant include a resin material.

The second encapsulant may include a filler. As described above, the second encapsulant has a higher Young's modulus than the first encapsulant, and it is easy to use a filler made of an inorganic material or the like as a means for increasing the Young's modulus.

The Young's modulus of the second encapsulant is preferably 5 ㎬ or more. It is more stably realized that the reactor body is fixed to the casing by the second sealing material.

The Young's modulus of the first encapsulant is preferably 50 MPa or less. It is possible to reduce the degree of compressive stress applied to the curved portion by the curing shrinkage when the first encapsulant is formed from the curable composition.

The magnetic powder may contain one or more amorphous magnetic material powders selected from the group consisting of Fe-Si-B alloys, Fe-P-C alloys and Co-Fe-Si-B alloys. Since the amorphous magnetic material is relatively hard, when the magnetic powder contains the powder of the amorphous magnetic material, it is likely to accumulate as deformation when an external force is applied to the core. The deformation accumulated in the core tends to adversely affect the magnetic characteristics of the reactor device having the core. However, as described above, in the reactor apparatus according to the present invention, the curing shrinkage of the curable composition for forming the sealing material located between the reactor main body and the casing hardly causes the deterioration of the magnetic characteristics of the reactor apparatus. Therefore, in the reactor device according to the present invention, even when the magnetic powder contained in the core contains an amorphous magnetic material, deterioration of magnetic properties is hardly caused.

The amorphous magnetic material may be made of an Fe-P-C alloy. Such a material may have a relatively high magnetostatic constant. Even in such a case, the reactor apparatus according to the present invention does not cause deterioration of magnetic properties.

The green compact may contain a binding component for binding the magnetic powder to another material contained in the green compact. In the case of having a binding component, it is relatively easy for the green compact to maintain its shape. Further, in some cases, the binder component is preferentially deformed between the magnetic powders. In this case, deformation is hardly accumulated in the magnetic powder. It is preferable that the binder component includes a component based on a resin material.

According to another aspect of the present invention, there is provided an electric / electronic device in which the reactor device according to the present invention is mounted.

According to the present invention, there is proposed a reactor apparatus capable of reducing the possibility of a problem that the reactor main body falls off from the casing during use, and suppressing a decrease in the magnetic characteristics of the reactor apparatus. An electric / electronic device including the reactor device is also provided.

1 is a perspective view conceptually showing the shape of a reactor device according to an embodiment of the present invention.
2 is a plan view conceptually showing the shape of a core of a reactor device according to an embodiment of the present invention.
3 is a plan view conceptually showing the shape of a reactor device according to an embodiment of the present invention.
Fig. 4 is a diagram conceptually showing a configuration of a sample used for evaluating the influence of the stress generated in the core on the iron loss in the embodiment. Fig.
5 is a graph showing a result of evaluating the influence of the stress generated on the core on the iron loss.
Figs. 6 (a) and 6 (b) conceptually illustrate a method for evaluating the effect of the external force applied to the core on the iron loss, which is performed in the embodiment. Fig.
7 is a graph showing the result of evaluating the influence of the external force application type on the core to the core loss.

Hereinafter, embodiments of the present invention will be described in detail.

1 is a perspective view conceptually showing the shape of a reactor device according to an embodiment of the present invention. 1, the reactor apparatus 100 includes a reactor body 20 having an annular core 10 in a plan view and a coil 15 wound around the core 10, a reactor main body 20, And a sealing material 40 to be filled between the reactor main body 20 and the casing 30. [

The core 10 is made of a press compaction core including a green compact obtained by pressure-molding a material containing magnetic powder. Fig. 2 is a plan view conceptually showing the shape of the core 10 provided in the reactor device 100. Fig. The core 10 made of a compaction core is annular in plan view and forms a closed magnetic path MP as shown in Fig. The core 10 includes two linear portions 12a and 12b having a portion inserted in the coil 15 and defining a linear magnetic path and a plurality of linear portions 12a and 12b continuously formed at the ends of the linear portions 12a and 12b, And two bending portions 11a and 11b that divide the formed magnetic path. The core 10 shown in Fig. 2 is composed of one green compact, but is not limited thereto. Or may be composed of a plurality of green compacts. As an example of such a case, there is a case where the straight portions 12a and 12b and the curved portions 11a and 11b are formed of individual green compacts, and the core as a whole is constituted by an annular shape in plan view.

The kind of the magnetic powder constituting the green compact is not limited. The magnetic material constituting the magnetic powder is largely classified into a crystalline magnetic material and an amorphous magnetic material.

The crystalline magnetic material is preferably a crystalline material (a material capable of obtaining a diffraction spectrum having a definite peak to the extent that the material type can be specified by general X-ray diffraction measurement), and a ferromagnetic material, particularly a soft magnetic material, Is not limited. Examples of the crystalline magnetic material include Fe-Si-Cr alloys, Fe-Ni alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe- Al-based alloys, carbonyl iron and pure iron. The crystalline magnetic material may be composed of one kind of material or a plurality of kinds of materials.

The amorphous magnetic material may be amorphous (as long as it is a ferromagnetic material, particularly a soft magnetic material) that is amorphous (that is, a diffraction spectrum having a clear peak can not be obtained to such an extent that a material type can be specified by general X- The specific kind is not limited. Specific examples of the amorphous magnetic material include Fe-Si-B alloys, Fe-P-C alloys and Co-Fe-Si-B alloys. The amorphous magnetic material may be composed of one kind of material or a plurality of kinds of materials.

An example of the composition of the Fe-PC based alloy which is an example of the amorphous magnetic material is as follows. The composition formula is represented by _{100 atom%} Fe- _abCxyzt Ni _a Sn _b Cr _c P _x C _y B _z Si _t , % ≤ a ≤ 10 atomic%, 0 atomic% ≤ b ≤ 3 atomic%, 0 atomic% ≤ c ≤ 6 atomic%, 6.8 atomic% ≤ x ≤ 10.8 atomic%, 2.2 atomic% ≤ y ≤ 9.8 atomic% %? Z? 4.2 atomic%, and 0 atomic%? T? 7 atomic%. In the above composition formula, Ni, Sn, Cr, B, and Si are optional additional elements.

When an amorphous magnetic material is used, the iron loss of the reactor device can be reduced as a basic tendency, as compared with the case of using a crystalline magnetic material. On the other hand, since a material having a relatively larger magneto-static constant is included than the crystalline magnetic material, when the reactor device is provided with a compaction core comprising a green compact containing a magnetic powder of an amorphous magnetic material, the curing shrinkage of the curable composition It is easy to affect the iron loss of In such a case, too, in the case of the reactor apparatus 100 according to the embodiment of the present invention, a plurality of kinds of the sealing materials 40 formed by curing the curable composition are used, and these sealing materials are arranged , Hardening shrinkage of the curable composition hardly affects the iron loss.

The shape of the magnetic powder is not limited and may be spherical or non-spherical. In the case of the non-spherical shape, it may be a shape having a shape anisotropy such as a scaly shape, an elliptic spherical shape, a liquid droplet shape, a needle shape, or the like, and may be a pseudo shape having no particular shape anisotropy. Examples of the amorphous powder include a case in which a plurality of spherical powders are bonded to each other or joined so as to be partially buried in other powders. The shape of the magnetic powder may be a shape obtained at the stage of manufacturing the magnetic powder, or a shape obtained by secondary working the produced magnetic powder. Examples of the former shape include spherical shape, elliptical spherical shape, droplet shape, needle shape and the like, and the latter shape exemplifies a scaly shape.

The size of the magnetic powder is not limited. As medicament glasses (D50) when laser diffraction / scattering type particle size distribution measurement is performed, 0.1 mu m or more and 100 mu m or more are exemplified, and it is preferable that the resolution is 1 mu m or more and 50 mu m or less.

The green compact may preferably contain a binder component that binds the magnetic powder to another material contained in the green compact. As the binder component, an insulating material is usually used. This makes it possible to improve the insulating property as a green compact. Examples of the insulating material include organic materials and inorganic materials such as a resin material and a pyrolysis residue of a resin material (in the present specification, these are collectively referred to as " components based on a resin material "). The binder component preferably contains a component based on a resin material from the viewpoint of productivity. As the resin material, acrylic resin, silicone resin, epoxy resin, phenol resin, urea resin, melamine resin and the like are exemplified. Examples of the binder component made of an inorganic material include glass-based materials such as water glass. The binder component may be composed of one kind of material or may be composed of a plurality of materials. The binding component may be a mixture of an organic-based material and an inorganic-based material.

The green compact is formed by press molding as described above. The conditions of the press-molding are not limited. And is appropriately set according to the composition of the material for forming the green compact. As a specific example of the pressing force, it is 0.1 ㎬ or more and 10 ㎬ or less. It may be heated at the time of pressure forming and may be pressurized at room temperature. The molded body after the pressure molding may be heated. By heating the molded body, the strain applied to the magnetic powder during pressure molding may be relaxed. The heating conditions are suitably set in accordance with the composition of the molded article. As a specific example of the heating conditions, the temperature is maintained at a temperature of 200 ° C to 500 ° C for 10 minutes to 10 hours.

The coil 15 is constituted by spirally winding a winding wire made of an insulating coated conductor around each of the linear portions 12a and 12b. A metal material such as copper or a copper alloy is preferably used for the conductor, and a resin material such as enamel is preferably used for the insulating coating. The cross-sectional shape of the winding is not limited. Circular, oval, square, and the like. The coil 15 may be wound over the whole of the linear portions 12a and 12b of the core 10 or may have a portion that is not wound.

The casing 30 has a shape on a container in which one surface is opened, and accommodates the reactor body 20 therein. The inside of the casing 30 may have a concavo-convex structure corresponding to the shape of the reactor body 20, and the reactor body 20 may be configured to be difficult to move within the casing 30. [ The open side of the casing 30 may be partially covered. The constituent material of the casing 30 is not limited. It is preferable that the material is excellent in heat radiation property. From this viewpoint, a metal material such as aluminum or an aluminum alloy is preferably used.

The sealing material 40 is positioned between the reactor main body 20 and the casing 30 to fix the reactor main body 20 to the casing 30. [ In the reactor device 100 according to the embodiment of the present invention, the sealing material 40 includes first sealing materials 41a and 41b positioned between the curved portions 11a and 11b and the casing 30, And a second encapsulant (42) positioned between the casing (30) and at least a portion of the straight sections (12a, 12b). The Young's modulus of the first encapsulant (41a, 41b) is lower than that of the second encapsulant (42). 3, in the reactor device 100, the second encapsulant 42 is positioned between the entire linear portions 12a and 12b and the casing 30. As shown in Fig.

As described above, the encapsulation material (the first encapsulation material 41a, 41b) located around the perforations 11a, 11b of the core and the encapsulation material (the second encapsulation material 42), the following effects can be obtained.

That is, since the curved portions 11a and 11b are different from the straight portions 12a and 12b and have a complicated shape, when the curable composition located around the curved portions 11a and 11b is contracted, the curved portions 11a, 11b are multi-direction including the direction in which the core is sheared. Therefore, even if the external force applied to the bending portions 11a, 11b is small, the iron loss of the reactor device having the core tends to increase.

Therefore, for the encapsulant (first encapsulant 41a, 41b) located around the perforations 11a, 11b, the Young's modulus is set relatively low, and the outer peripheries of the perforations 11a, It is possible to suppress an increase in iron loss of the reactor apparatus 100 caused by the shrinkage of the first sealing members 41a and 41b.

The specific numerical values of the Young's modulus of the first encapsulant 41a, 41b are not limited. The shape and composition of the loop portions 11a and 11b and the characteristics of the curable composition for forming the first encapsulant 41a and 41b and the like are suitably adjusted so as to reduce the influence on the core loss of the reactor 100 You can set it. By way of non-limiting example, the Young's modulus of the first encapsulant 41a, 41b is preferably 100 MPa or less, more preferably 50 MPa or less, particularly preferably 10 MPa or less. The lower limit of the Young's modulus of the first encapsulant 41a or 41b is not set from the viewpoint of reducing the influence on the iron loss of the reactor device 100. [ If the Young's modulus of the first encapsulant 41a or 41b is excessively low, even if the Young's modulus of the second encapsulant 42 is increased as described below, the fixing of the reactor main body 20 to the casing 30 becomes unstable There is a tendency to be seen. Therefore, the Young's modulus of the first encapsulant 41a (41b) is preferably 0.1 MPa or more, and it is more preferable that the Young's modulus is 1 MPa or more.

Since the hardening shrinkage of the curable composition located around the linear portions 12a and 12b hardly affects the iron loss of the reactor apparatus 100, the Young's modulus of the second encapsulant 42 is increased, (20) can be securely fixed to the casing (30).

The specific value of the Young's modulus of the second encapsulant 42 is not limited. The reactor main body 20 can be suitably fixed to the casing 30 in consideration of the shape and the composition of the linear portions 11a and 11b and the characteristics of the curable composition for forming the second encapsulant 42, You can set it. By way of example and not limitation, the Young's modulus of the second encapsulant 42 is preferably 1 ㎬ or more, more preferably 5 ㎬ or more, and particularly preferably 20 ㎬ or more. The lower limit of the Young's modulus of the second encapsulant 42 is not limited. When the Young's modulus of the second encapsulant 42 is excessively high, there is a case that the second encapsulant 42 tends to be easily cracked due to vibration or the like generated in the reactor device 100 . Therefore, the Young's modulus of the second encapsulant 42 is preferably 100 ㎬ or less, and more preferably 70 ㎬ or less.

The composition of the first encapsulant 41a, 41b and the composition of the second encapsulant 42 are not limited as long as they satisfy the conditions relating to the Young's modulus. The first encapsulant 41a, 41b and the second encapsulant 42 preferably comprise a resin-based material from the viewpoints of availability and handleability. In this case, the curable composition for forming any encapsulation material is a material containing a curable resin. Examples of such a resin material include thermosetting resins such as epoxy resin, silicone resin, phenol resin and melamine resin and thermoplastic resins having heat resistance (high softening point) such as polyphenylene sulfide (PPS) and liquid crystal polymer (LCP) And those obtained by adding a crosslinking agent such as an isocyanate to a thermoplastic resin such as polyester (PE) to improve the curability. In addition, the curable composition may contain a filler made of an inorganic material such as alumina, silica, silicon nitride, aluminum nitride, boron nitride, silicon carbide, or the like. By changing the content of the curable composition of the filler, the Young's modulus of the encapsulant 40 can be adjusted.

As a specific example of the composition of the first encapsulant 41a, 41b, a silicone resin which is a relatively soft thermosetting resin is used as the main component of the curable resin and alumina is used as the filler. As a specific example of the composition of the second encapsulant 42, an epoxy resin which is a relatively hard thermosetting resin is used as the main component of the curable resin and alumina is used as the filler.

As the electric / electronic device in which the reactor device 100 is mounted, a converter equipped with the reactor device 100 is exemplified. Particularly, in a hybrid vehicle or an electric vehicle, a converter that performs voltage up / down pressure is a vehicle component, so that it is required to have high reliability particularly in an environment in which it receives an external force such as vibration. The reactor device 100 according to the embodiment of the present invention is less susceptible to the curing shrinkage of the curable composition for forming the encapsulant 40 from affecting the iron loss of the reactor device 100, 20 are firmly fixed with respect to the casing 30. Even when an external force is applied to the reactor device 100, the sealing material (the first sealing materials 41a and 41b) located around the circumferential portions 11a and 11b, The external force applied to the reactor device 100 is difficult to be transmitted to the bending portions 11a and 11b. Therefore, the reactor device 100 according to one embodiment of the present invention can be preferably used as a converter for vehicle use.

(Example)

Hereinafter, the present invention will be described in more detail with reference to Examples and the like, but the scope of the present invention is not limited to these Examples and the like.

(1) Preparation of Fe-based amorphous alloy powder

The raw material was weighed so that the composition of Fe _{74.28 atomic%} Cr _{1.56 atomic%} P _{8.78 atomic%} C _{2.62 atomic%} B _{7.57 atomic%} Si _{5.19 atomic%} , and powder of an amorphous magnetic material was prepared by using the Toze-Is method. The particle size distribution of the amorphous magnetic material powder thus obtained was measured by volume distribution using "Microtrack particle size distribution measuring apparatus MT3300EX" manufactured by Nikkiso Co., Ltd., and the 50% cumulative diameter of the cumulative particle size distribution on the volume basis d2)) (D50) was 5 to 20 占 퐉.

(2) Production of granulated powder

97.7 parts by mass of a magnetic powder composed of the amorphous magnetic material powder, 2.0 parts by mass of an insulating binder made of an acrylic resin, and 0.3 parts by mass of a lubricant were mixed with water as a solvent to obtain a slurry.

The obtained slurry was pulverized after being dried, and a granulated product consisting of a powder passed through a 300 mu m mesh was obtained using a sieve having a mesh of 300 mu m.

(3) Compression molding

The obtained granulated powder was filled in a metal mold and pressure-molded under a surface pressure of 1.77 mm to obtain a molded body having a ring shape having an outer diameter of 20.7 mm x inner diameter of 12.4 mm x thickness of 6.8 mm. Further, the resultant was filled in a separate mold and subjected to pressure molding at a surface pressure of 1.77 mm to obtain a molded body having a prismatic shape with a bottom surface of 10 mm x 10 mm and a height of 48 mm.

(4) Heat treatment

Each of the obtained molded bodies was placed in a furnace in a nitrogen gas stream atmosphere and the furnace temperature was heated from room temperature (23 DEG C) to 370 DEG C at a heating rate of 10 DEG C / min and maintained at this temperature for 1 hour Thereafter, a heat treatment was performed to cool the furnace to room temperature. Thus, a green compact in a ring shape and a green compact in a bar shape were obtained.

(Test Example 1) Measurement of iron loss (Pcv)

As shown in Fig. 4, the troidal core made of the ring-shaped green compact manufactured as described above has one point (the measuring direction is the radial direction) and two points (the measuring direction is the thickness direction and the circumferential direction) , And the stress applied to the Troydal core was measured based on the signals from these strain gauges. The Troydal core obtained by winding coated copper wires 15 times on the primary side and 10 times on the secondary side respectively was connected to this Troydal core and connected to a BH analyzer ("SY-8218" manufactured by Iwasaki Communication Co., Ltd.) / M < 3 >). In this state, the iron loss (Pcv) was measured under the conditions of the effective maximum magnetic flux density (Bm) of 100 mT and the measurement frequency of 100 kHz, and the iron loss was defined as a reference value Pcv0.

A curable composition (also referred to as " curable composition II ") comprising a curable composition (also referred to as " curable composition I ") or a silicone resin comprising an epoxy resin and a Troydal coil disposed in a container capable of accommodating a Troydale coil. ) Was poured into the container, and the entire container was heated to cure the resin. With the resin in the cured state, the average stress applied to the Troydal core was calculated based on the signals from the strain gages at three points. As a result, it was confirmed that different compressive stresses were given depending on the kind of the resin and the particle size distribution of the green compact. As a basic tendency, in the case of the curable composition II in which the Young's modulus of the cured product is low, the compressive stress is low (negative value and close to zero), and in the case of the curable composition I having a high Young's modulus of the cured product, Stress (negative value for stress value, far from zero). The iron loss (Pcv) of the Troydal coil was measured under the conditions of the effective maximum magnetic flux density (Bm) of 100 mT and the measurement frequency of 100 kHz. From the obtained iron loss (Pcv), an increase rate of the iron loss with respect to the reference value Pcv0 was determined. As a basic tendency, in the case of the curable composition II in which the Young's modulus of the cured product is low, the rate of increase of the iron loss (Pcv) is low and in the case of the curable composition I in which the Young's modulus of the cured product is high, the rate of increase of the iron loss (Pcv) is increased.

A ferrite yoke was mounted so as to wind a coil on the side surface of the compact dust core composed of the rod-like green compact and to guide the magnetic flux from one end surface to the other end surface. The obtained inductor was mounted on a BH analyzer -8218 ") to make it possible to measure iron loss (Pcv) (unit: kW / m3). The iron loss (Pcv) was measured in this state, and the iron loss (Pcv) was set as a reference value Pcv0 of iron loss.

The inductor was mounted on a tensile tester so as to be compressible on both end faces of the compaction core and the core loss (Pcv) was measured while varying the compressive force applied to both end faces of the compaction core. As a result, as the compressive force applied to both end faces of the compact cored core increases, the rate of increase of the iron loss also increases.

The above results are shown in Fig. As shown in Fig. 5, both of the measurement results of the ring-shaped compact cores and the measurement results of the stick-shaped compact cores show a tendency that the increase rate of the iron loss tends to increase when the compressive stress generated in the cores increases, It was possible to approximate linearly (Fig. 5 dashed line).

(Test Example 2)

A Troydal coil having a Troydal core composed of the ring-shaped green compact was produced in the same manner as in Test Example 1, and connected to a BH analyzer ("SY-8218" manufactured by Iwasaki Communication Co., Ltd.) : kW / m < 3 >). In this state, the iron loss (Pcv) was measured under the conditions of the effective maximum magnetic flux density (Bm) of 100 mT and the measurement frequency of 100 kHz, and the iron loss was defined as a reference value Pcv0.

6 (a) or 6 (b), the torsional coil is placed in a tensile tester and is subjected to an external force in the radial direction (circular load) and an external force in the thickness direction (Pcv) was measured under the above conditions (effective maximum magnetic flux density (Bm) of 100 mT and measurement frequency of 100 kHz) while an external force was applied to each of the case (sectional load) Therefore, how the growth rate of core loss changes is measured.

As a result, as shown in Fig. 7, it was confirmed that the influence of the external force on the rate of increase of the iron loss was ten times greater at the toric load than in the case of the section load.

From the above results, in the compaction core, the degree of increase in the external force is not so large in the portion having a simple shape that divides the straight line-shaped magnetic path, but in the portion having the complicated shape for dividing the bent magnetic path It was confirmed that the increase of the external force is easy to increase the iron loss. Therefore, by changing the Young's modulus of the sealing material located in the reactor body according to the shape of the core, as in the reactor device according to the present invention, the iron loss of the reactor device is increased due to the curing shrinkage of the curable composition for forming the sealing material Can be suppressed.

The reactor device of the present invention can be suitably used as an inductor such as a transformer or a choke coil as a component of a vehicle-use converter.

100: reactor device
10: Core
11a and 11b:
12a and 12b:
15: Coil
20: Reactor body
30: casing
40: sealing material
41a, 41b: a first encapsulant
42: Second encapsulant
MP:

Claims (10)

A reactor main body having an annular core and a coil wound around the core in plan view,
A casing accommodating the reactor main body, and
And an encapsulating material filled between the reactor main body and the casing,
Wherein the core comprises a compacted core comprising a green compact obtained by press-molding a material containing magnetic powder,
Wherein the core has two straight portions having a portion inserted in the coil and defining a straight line, and two curved portions that are formed continuously and formed on each end of the straight portion to form a curved magnetic path,
Wherein the sealing member comprises a first sealing member positioned between the curved portion and the casing and a second sealing member positioned between at least a part of the straight portion and the casing,
Wherein the Young's modulus of the first encapsulant is lower than the Young's modulus of the second encapsulant. The method according to claim 1,
Wherein the first encapsulant and the second encapsulant comprise a resin material. 3. The method according to claim 1 or 2,
Wherein the second encapsulant comprises a filler. 3. The method according to claim 1 or 2,
And the Young's modulus of the first encapsulant is 50 MPa or less. 3. The method according to claim 1 or 2,
And the Young's modulus of the second encapsulant is 5 ㎬ or more. 3. The method according to claim 1 or 2,
Wherein the magnetic powder comprises a powder of one or more amorphous magnetic materials selected from the group consisting of an Fe-Si-B alloy, an Fe-PC alloy and a Co-Fe-Si-B alloy, . The method according to claim 6,
Wherein the amorphous magnetic material is made of an Fe-PC based alloy. 3. The method according to claim 1 or 2,
Wherein the green compact contains a binding component for binding the magnetic powder to another material contained in the green compact. 9. The method of claim 8,
Wherein the binder component comprises a component based on a resin material. An electric / electronic device in which the reactor device according to claim 1 or 2 is mounted.

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