WO2012066938A1 - リアクトル - Google Patents
リアクトル Download PDFInfo
- Publication number
- WO2012066938A1 WO2012066938A1 PCT/JP2011/075375 JP2011075375W WO2012066938A1 WO 2012066938 A1 WO2012066938 A1 WO 2012066938A1 JP 2011075375 W JP2011075375 W JP 2011075375W WO 2012066938 A1 WO2012066938 A1 WO 2012066938A1
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- WIPO (PCT)
- Prior art keywords
- coil
- heat dissipation
- bottom plate
- reactor
- core
- Prior art date
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/008—Details of transformers or inductances, in general with temperature compensation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/02—Casings
- H01F27/025—Constructional details relating to cooling
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/08—Cooling; Ventilating
- H01F27/22—Cooling by heat conduction through solid or powdered fillings
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F37/00—Fixed inductances not covered by group H01F17/00
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core
Definitions
- the present invention relates to a reactor used for a component part of a power conversion device such as an in-vehicle DC-DC converter mounted on a vehicle such as a hybrid vehicle, and a manufacturing method thereof.
- the present invention relates to a reactor that is small and excellent in heat dissipation.
- Patent Document 1 discloses a reactor used in a converter mounted on a vehicle such as a hybrid vehicle.
- the reactor includes a coil, an annular magnetic core in which the coil is disposed, a case that houses an assembly of the coil and the magnetic core, and a sealing resin that is filled in the case.
- This reactor is generally used by being fixed to a cooling base in order to cool a coil that generates heat when energized.
- the case is typically an aluminum die-cast product, and is used as a heat dissipation path for fixing heat to the coil and the like by being fixed to the cooling base.
- the reactor can be downsized by omitting the case.
- the coil and the magnetic core are exposed, it is impossible to protect the coil and the magnetic core from the external environment such as dust and corrosion and mechanical protection such as strength.
- the sealing resin filled in the case is excellent in heat dissipation.
- heat dissipation can be improved by using a resin containing a filler made of ceramics as a sealing resin.
- the resin containing the filler is contained in the case so that no gaps or voids are generated between the combination and the inner surface of the case. If it tries to fill, it will take time and it will be inferior to the productivity of a reactor.
- heat dissipation can be improved by raising the content rate of the filler in sealing resin, since sealing resin becomes embrittled, it becomes easy to be damaged by a thermal shock. Therefore, development of a reactor excellent in heat dissipation is desired without using a sealing resin containing a filler.
- one of the objects of the present invention is to provide a reactor that is small and excellent in heat dissipation. Moreover, the other object of this invention is to provide the manufacturing method of the said reactor.
- the case has a split structure, a heat radiating layer having excellent heat radiating properties is provided at a portion constituting the inner bottom surface of the case, and a surface disposed on the inner bottom surface side of the case is pressed against the heat radiating layer in the coil.
- the reactor of the present invention includes a combined body having a coil formed by winding a winding in a spiral shape and a magnetic core on which the coil is disposed, and a case for storing the combined body.
- the combination includes an insulator that insulates the coil from the magnetic core.
- the case includes a bottom plate portion that is fixed to the fixation target when the reactor is installed on the fixation target, a side wall portion that is attached to the bottom plate portion with a fixing material, and surrounds the periphery of the combination, and the bottom plate portion. And a heat radiation layer interposed between the bottom plate portion and the coil.
- the thermal conductivity of the bottom plate portion is equal to or higher than the thermal conductivity of the side wall portion, and the heat dissipation layer is made of an insulating material having a thermal conductivity of more than 2 W / m ⁇ K.
- the insulator includes an installation surface portion interposed between the inner peripheral surface of the coil and the magnetic core, and the installation surface portion for uniformly contacting the coil with the heat dissipation layer. A pressing mechanism that presses against the surface. “Insulating” of the insulating material means having a withstand voltage characteristic such that the coil and the bottom plate portion can be electrically insulated.
- the method of manufacturing a reactor according to the present invention includes assembling a coil formed by winding a winding in a spiral shape and a magnetic core to produce an assembly of the coil and the magnetic core, and standing on the bottom surface portion and the bottom surface portion.
- the following heat dissipation layer forming step, coil pressing step, and case assembly step are provided.
- Step of forming a heat dissipation layer A step of forming a heat dissipation layer made of an insulating material having a thermal conductivity of more than 2 W / m ⁇ K on the inner surface of the bottom plate portion of the case.
- Coil pressing step a step of placing an insulator that insulates between the coil and the magnetic core, pressing the coil against the heat dissipation layer with the insulator, and bringing the coil into uniform contact with the heat dissipation layer .
- Case assembling step A step of attaching the side wall portion to the bottom plate portion with a fixing material to form the case. Note that either the coil pressing step or the case assembly step may be performed first.
- the coil installation surface since the surface on the installation side (hereinafter referred to as the coil installation surface) is brought into contact with the heat dissipation layer when the reactor is installed on the fixed object in the coil, the heat of the coil is efficiently radiated. It is transmitted to the layer, and can be discharged to a fixed object such as a cooling base through the heat dissipation layer, and is excellent in heat dissipation.
- the heat dissipation layer is made of an insulating material, even when the bottom plate portion is made of a conductive material, the coil and the bottom plate portion can be reliably insulated by contacting the coil with the heat dissipation layer. .
- the heat dissipation layer can be made thin. From this point as well, the heat of the coil can be easily released to the fixed object, and the reactor of the present invention is excellent in heat dissipation.
- the bottom plate portion is made of a material having a thermal conductivity at least equal to or higher than the thermal conductivity of the side wall portion, so that heat from the coil installation surface can be efficiently released through the heat dissipation layer.
- This invention reactor is excellent in heat dissipation.
- the bottom plate portion and the side wall portion are separate members, both can be made of different materials.
- the bottom plate portion is made of a material having a higher thermal conductivity than the side wall portion. Furthermore, it can be set as the reactor which is excellent in heat dissipation.
- the coil is pressed against the heat dissipation layer by the insulator, more specifically, the installation surface portion of the insulator presses the inner peripheral surface of the coil by the pressing mechanism.
- the created turns are aligned so that the heat dissipation layer can be uniformly contacted. That is, a sufficient contact area between the coil installation surface and the heat dissipation layer can be secured, and the reactor of the present invention is also excellent in heat dissipation from this point.
- a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor made of a conductive material is widely used.
- the outer dimension (outer dimension) of the coil includes the dimensional error at the time of winding and the winding dimension.
- An error (a dimensional error of the conductor and a dimensional error of the insulation coating (a maximum of twice the thickness)) is added as a dimensional error.
- the maximum dimensional error on one side of the rectangle is the sum of the dimensional error at the time of winding and twice the dimensional error of the winding. It will be. Due to these errors, the accuracy of the outer dimension of the coil tends to be lowered. That is, the outer peripheral surface of the coil formed by arranging a plurality of turns in parallel tends to be uneven, and the turns constituting the coil installation surface may not be sufficiently adhered to the heat dissipation layer.
- the conductor is a flat wire and the rectangular coil is formed by edgewise winding, springback will occur if it is bent at right angles (90 °) when forming the corner. Bend at an angle with a margin for springback.
- the weight of the coil after winding increases, so that even when bending with the above margin is performed, the bending angle shifts due to inertia.
- the winding amount of the winding wound around the feeding bobbin that supplies the winding also increases. Therefore, depending on the position of the winding wound around the feeding bobbin, for example, the winding angle differs between the initial stage and near the final stage, so that the bending angle differs.
- the corner portion of each turn appears to be slightly shifted like a spiral staircase due to such a deviation in bending state. Even from this deviation, the outer peripheral surface of the coil becomes uneven, and the turn constituting the coil installation surface may not be sufficiently adhered to the heat dissipation layer.
- the corner portion bent at 90 ° in the edgewise coil is particularly difficult to correct the angular deviation for each turn because the flat wire is work hardened.
- the coil installation surface can be made closer to a smooth surface from an uneven shape, or can be made a substantially smooth surface.
- the contact area with the heat dissipation layer can be increased, and preferably, all the turns constituting the coil installation surface can be reliably brought into contact with the heat dissipation layer.
- the insulators are configured such that the turns that press the inner peripheral surface of the coil to form the coil installation surface can be aligned. Further, by aligning the turns, the corner portions of the turns can be aligned even with the rectangular coil. Therefore, a part of the corner portion protrudes due to the above-described deviation, and the heat dissipation layer is not damaged by the protruding portion. Therefore, even when the case is made of a conductive material such as a metal material, the insulation between the coil and the case can be sufficiently secured by the heat dissipation layer made of the insulating material. Furthermore, by providing the insulator, the reactor of the present invention can enhance the insulation between the coil and the magnetic core.
- the reactor of the present invention since the bottom plate portion and the side wall portion are separate members, both constituent materials can be easily changed.
- the side wall portion is made of a material excellent in electrical insulation, the distance between the outer peripheral surface of the coil and the inner peripheral surface of the side wall portion can be reduced, so that a smaller reactor can be achieved.
- the heat dissipation layer since the heat dissipation layer is provided, heat can be efficiently radiated at least from the coil installation surface via the heat dissipation layer as described above.
- the case is filled with a sealing resin.
- the degree of freedom in selecting an available sealing resin can be increased. For example, a resin containing no filler can be used. Or even if it is a form which does not have sealing resin, sufficient heat dissipation can be secured by a heat dissipation layer.
- the heat radiation layer can be formed with the side wall portion removed.
- a heat radiation layer can be formed on the inner bottom surface where the coil can contact.
- the side wall is obstructive and it is difficult to form the heat dissipation layer.
- a thermal radiation layer can be formed easily and it is excellent also in the manufacturability of a reactor.
- the reactor of the present invention by providing the case, protection of the coil and the magnetic core from the environment and mechanical protection can be achieved.
- the said magnetic core is provided with the inner core part by which the said coil is arrange
- the said insulator is the said inner core part.
- a peripheral wall disposed on the outer periphery and interposed between the coil and the inner core, and a frame shape that is in contact with the end surface of the coil and interposed between the coil and the outer core.
- which comprises a part is mentioned.
- the peripheral wall portion and the frame-shaped portion have an engaging portion that engages with each other, the peripheral wall portion has the installation surface portion, and the frame-shaped portion is combined with the peripheral wall portion.
- a protrusion is provided that presses the installation surface against the inner peripheral surface of the coil, and the pressing mechanism is configured by the engagement portion and the protrusion.
- an insulator is assembled and the frame-shaped part engaged with an installation surface part is pressed, the projection part of the said frame-shaped part presses an installation surface part to the thermal radiation layer side, and also the said installation surface part is a coil. Press the inner surface against the heat dissipation layer.
- the turns constituting the inner peripheral surface of the coil are aligned, the inner peripheral surface becomes a smooth surface, and the outer peripheral surface of the coil facing the inner peripheral surface is also likely to be a smooth surface. That is, the unevenness due to the error is corrected on the coil installation surface, and a sufficient contact area with the heat dissipation layer can be secured.
- the outer peripheral surface of the coil can be made closer to a plane, and the coil installation surface and the heat dissipation layer It is easy to secure the contact area.
- an edgewise coil using a winding in which a conductor is a rectangular wire it is easy to make a coil with a high space factor, and it is easy to reduce the size.
- the heat dissipation layer has a multilayer structure made of an insulating adhesive and the bottom plate part is made of a conductive material.
- the adhesion between the coil and the heat dissipation layer can be improved.
- the installation side region of each turn of the coil is aligned by the insulator, so that the coil can sufficiently adhere to the heat dissipation layer made of the insulating adhesive.
- an electrical insulation performance can be improved.
- the adhesive layer is made as thin as possible, the distance between the coil and the bottom plate portion can be shortened, so that the reactor can be made small.
- the adhesive layer is made thin, pinholes may exist.
- a heat dissipation layer having excellent insulating performance can be obtained.
- the thickness per one layer and the number of layers can be selected as appropriate. The thicker the total thickness, the higher the insulation, and the thinner the heat dissipation. As long as the material has excellent insulation performance, each adhesive layer is thin, and even if the number of laminated layers is small, sufficient heat dissipation and insulation can be obtained.
- a heat dissipation layer having a total thickness of less than 2 mm, further 1 mm or less, particularly 0.5 mm or less can be obtained.
- the bottom plate portion is made of a conductive material, typically a metal such as aluminum, these metals are generally excellent in heat dissipation, so that the heat dissipation of the reactor can be further enhanced. Further, even if the bottom plate portion is made of a conductive material, as described above, since the heat dissipation layer is made of an insulating material, electrical insulation between the coil and the bottom plate portion can be ensured. .
- the side wall portion is made of an insulating material.
- the side wall portion can also be made of a conductive material such as aluminum as described above. In this case, heat dissipation can be improved. In addition, since the case is made of a conductive and nonmagnetic material, the case functions as a magnetic shield and leakage flux can be suppressed. On the other hand, since the side wall portion is made of an insulating material, the side wall portion and the coil are insulated from each other. Therefore, the distance between the inner surface of the side wall portion and the outer peripheral surface of the coil can be reduced, and further miniaturization can be achieved. be able to. If the insulating material is lighter than a metal material such as a resin, the case can be made lighter than a conventional aluminum case.
- the heat dissipation layer has a multilayer structure composed of an epoxy-based adhesive containing an alumina filler, the bottom plate portion is composed of aluminum or an aluminum alloy, and the side wall portion is composed of an insulating resin.
- a configured form is mentioned.
- the epoxy adhesive containing the alumina filler is excellent in both insulation and heat dissipation, and can satisfy, for example, a thermal conductivity of 3 W / m ⁇ K or more. Therefore, according to the said form, it is further excellent in heat dissipation. Moreover, by using a multilayer structure, high electrical insulation can be ensured even if each adhesive layer is thinned as described above. Moreover, by reducing the thickness of each adhesive layer, the reactor can be downsized as described above. Furthermore, aluminum or an aluminum alloy has a high thermal conductivity (aluminum: 237 W / m ⁇ K).
- the heat of the coil can be efficiently released to a fixed object such as a cooling base using the bottom plate portion as a heat dissipation path, and the heat dissipation is further improved.
- the said form which provides the side wall part which consists of insulating resin since the space
- the reactor of the present invention is small and has excellent heat dissipation.
- FIG. 1 is a schematic perspective view showing a reactor according to the embodiment.
- FIG. 2 is an exploded perspective view schematically showing the reactor according to the embodiment.
- FIG. 3 (A) is an exploded perspective view showing an outline of a combination of a coil and a magnetic core included in the reactor of the embodiment, and
- FIG. 3 (B) shows an outline of an inner core portion constituting the magnetic core. It is a disassembled perspective view.
- FIG. 4 (A) is a schematic perspective view of an insulator provided in the reactor of the embodiment, and FIG. 4 (B) is a plan view of the insulator.
- FIG. 5 is a schematic cross-sectional view of a combination of a coil and a magnetic core included in the reactor according to the embodiment cut along the axial direction of the coil.
- FIG. 1 is a schematic perspective view showing a reactor according to the embodiment.
- FIG. 2 is an exploded perspective view schematically showing the reactor according to the embodiment.
- FIG. 3 (A) is an exploded perspective
- FIG. 6 is an explanatory view illustrating a process of assembling an assembly of a coil and a magnetic core included in the reactor according to the embodiment.
- FIG. 7 is an exploded perspective view showing an outline of another form of a combination of a coil and a magnetic core.
- the reactor 1 includes a combination 10 of a coil 2 and a magnetic core 3 on which the coil 2 is disposed, and a case 4 that houses the combination 10.
- the case 4 is a box that is open on one side, typically filled with sealing resin (not shown), and the assembly 10 is sealed except for the end of the winding 2w that forms the coil 2. Embedded in resin.
- the combined body 10 includes an insulator 5 that insulates the coil 2 from the magnetic core 3.
- the features of the reactor 1 are that the case 4 has a structure that can be divided and the shape of the insulator 5.
- each component will be described in more detail.
- the coil 2 includes a pair of coil elements 2a and 2b formed by spirally winding a single continuous winding 2w having no joint part, and a coil connecting part 2r for connecting both the coil elements 2a and 2b.
- Each coil element 2a, 2b has the same number of turns, and the shape (end face shape) viewed from the axial direction is substantially rectangular (rectangular shape with rounded corners).
- These coil elements 2a and 2b are arranged side by side so that their axial directions are parallel to each other, and a part of the winding 2w is U-shaped on the other end side of the coil 2 (the back side in FIG. 2).
- a coil connecting portion 2r is formed by bending. With this configuration, the winding directions of both coil elements 2a and 2b are the same.
- the winding 2w is preferably a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor made of a conductive material such as copper or aluminum.
- a coated rectangular wire is used in which the conductor is made of a rectangular copper wire and the insulating coating is made of enamel (typically polyamideimide).
- the thickness of the insulating coating is preferably 20 ⁇ m or more and 100 ⁇ m or less, and the thicker the pinholes can be reduced and the electrical insulation can be improved.
- Both coil elements 2a, 2b are formed in a hollow rectangular tube shape by winding the above-mentioned covered rectangular wire edgewise.
- the winding 2w can be used in various shapes such as a circular shape, an elliptical shape, a polygonal shape, etc., in addition to the conductor made of a rectangular wire.
- a flat wire is easier to form a coil having a higher space factor than when a round wire having a circular cross section is used.
- the surface on the installation side when the reactor 1 is installed on the fixed object in the coil 2 (coil installation surface 2d (FIG. 5)) is based on the product of the thickness of the flat wire and the number of turns. Since it has an area substantially, it is easier to ensure a wide contact area with the heat-dissipating layer 42 described later than when a round wire is used.
- it can be set as the form which produced each coil element by a separate coil
- Both end portions of the winding 2w forming the coil 2 are appropriately extended from the turn forming portion on one end side of the coil 2 (front side in FIG. 2) and pulled out of the case 4 (FIG. 1).
- the terminal fitting 8 made of a conductive material is connected to the conductor portion exposed by peeling off the insulation coating.
- An external device such as a power source for supplying power is connected to the coil 2 via the terminal fitting 8. Details of the terminal fitting 8 will be described later.
- the magnetic core 3 includes a pair of inner core portions 31 where the coil elements 2a and 2b are respectively disposed, and a pair of outer core portions 32 where the coil 2 is not disposed and is exposed from the coil 2.
- each inner core portion 31 has a rectangular parallelepiped shape (here, corner portions are rounded), and each outer core portion 32 has a prismatic body having a pair of trapezoidal surfaces.
- the magnetic core 3 has an outer core portion 32 disposed so as to sandwich the inner core portion 31 that is spaced apart, and the end surface 31e of each inner core portion 31 and the inner end surface 32e of the outer core portion 32 are in contact with each other to form an annular shape. Formed.
- the inner core portion 31 and the outer core portion 32 form a closed magnetic path when the coil 2 is excited.
- the inner core portion 31 is a laminate formed by alternately laminating core pieces 31m (omitted in FIG. 5) made of a magnetic material and gap members 31g (omitted in FIG. 5) typically made of a non-magnetic material.
- the outer core portion 32 is a core piece made of a magnetic material (FIG. 3B).
- As each core piece a molded body using magnetic powder or a laminated body in which a plurality of magnetic thin plates (for example, electromagnetic steel plates) having an insulating coating are laminated can be used.
- Examples of the molded body include iron group metals such as Fe, Co, and Ni, Fe-based alloys such as Fe-Si, Fe-Ni, Fe-Al, Fe-Co, Fe-Cr, and Fe-Si-Al, and rare earth metals.
- examples of the core piece include a ferrite core that is a sintered body of a metal oxide. The molded body can easily form various three-dimensional magnetic cores.
- a powder having an insulating coating on the surface of the powder made of the soft magnetic material can be suitably used.
- heat treatment is performed at a temperature lower than the heat resistance temperature of the insulating coating. It is obtained by applying.
- the insulating coating includes a silicone resin or a phosphate.
- the material of the inner core portion 31 and the material of the outer core portion 32 can be made different.
- the saturation magnetic flux density of the inner core portion 31 can be easily increased as compared with the outer core portion 32.
- each core piece is a compacted body of soft magnetic powder containing iron such as iron or steel.
- the gap material 31g is a plate-like material disposed in a gap provided between the core pieces 31m for adjusting the inductance, and is a material having a lower magnetic permeability than the core piece, such as alumina, glass epoxy resin, and unsaturated polyester. Typically, it is made of a nonmagnetic material (in some cases, an air gap).
- the number of core pieces and gap materials can be appropriately selected so that the reactor 1 has a desired inductance.
- the shape of a core piece or a gap material can be selected suitably.
- the inner core portion 31 shows a form composed of a plurality of core pieces 31m and a plurality of gap members 31g.
- the inner core part 31 may have one gap member or no gap member depending on the material of the core pieces.
- each outer core portion 32 shows a form constituted by a single core piece, but may be constituted by a plurality of core pieces. In the case where the core piece is formed of a compacted body, when the inner core portion and the outer core portion are configured by a plurality of core pieces, each core piece can be made small, and thus the moldability is excellent.
- the outer periphery of the inner core portion 31 is provided with a coating layer made of an insulating material, the insulation between the coil 2 and the inner core portion 31 can be improved.
- the said coating layer is provided by arrange
- the core piece and the gap material can be integrated.
- the installation side surface of the inner core portion 31 and the installation side surface of the outer core portion 32 are not flush with each other.
- a surface on the installation side in the outer core portion 32 (hereinafter referred to as a core installation surface 32d; the lower surface in FIGS. 3 and 5).
- the inner core portion 31 protrudes from the surface on the installation side.
- the core installation surface 32d of the outer core portion 32 and the surface on the installation side in the coil 2 (hereinafter referred to as the coil installation surface 2d, the lower surface in FIGS. 3 and 5) are flush with each other, and
- the facing surface upper surface in FIGS.
- the magnetic core 3 has a shape obtained by rotating 90 degrees counterclockwise when viewed through from the side in a state where the reactor 1 is installed.
- the core installation surface 32d and the coil installation surface 2d are flush with each other, not only the coil installation surface 2d of the coil 2 but also the core installation surface 32d of the magnetic core 3 is formed on the heat dissipation layer 42 (FIG. 2) described later. Can touch. Further, in a state where the magnetic core 3 is assembled in an annular shape, the side surface of the outer core portion 32 (the front side and the back surface in FIG. 3) protrudes outward from the side surface of the inner core portion 31. Therefore, the magnetic core 3 is H-shaped when seen through from the upper surface or the lower surface in a state where the reactor is installed (in a state where the lower side is the installation side in FIG. 3).
- Such a three-dimensional magnetic core 3 can be easily formed by forming a compacted body, and a portion protruding from the inner core portion 31 in the outer core portion 32 can also be used as a magnetic flux passage. . Further, the assembly 10 is stably installed because the core installation surface 32d and the coil installation surface 2d are flush with each other.
- the insulator will be described with reference to FIGS. 3 to 5 as appropriate.
- the combined body 10 includes an insulator 5 between the coil 2 and the magnetic core 3 to enhance insulation between the coil 2 and the magnetic core 3.
- the insulator 5 includes a peripheral wall portion 51 disposed on the outer periphery of the inner core portion 31 and a pair of frame-like portions 52 that are in contact with the end surface of the coil 2 (surface on which the turn of the coil element appears to be annular). Is mentioned.
- FIG. 4 (A) the peripheral wall portion 51 arranged on one inner core portion is omitted, and in FIG. 4 (B), only the vicinity of one peripheral wall portion 51 is shown.
- the peripheral wall portion 51 is interposed between the inner peripheral surface of the coil 2 and the outer peripheral surface of the inner core portion 31 to insulate between the coil 2 and the inner core portion 31.
- the peripheral wall 51 is constituted by a pair of divided pieces 511 and 512.
- Each of the divided pieces 511, 512 does not contact each other, and only a part of the outer peripheral surface of the inner core portion 31 (here, the surface on the installation side of the inner core portion 31 (lower surface in FIG. 5) and its opposite surface (upper surface in FIG. 5). )),
- the divided pieces 511 and 512 are arranged.
- Each of the divided pieces 511 and 512 includes a flat plate portion 513 disposed along the surface on the installation side of the inner core portion 31 and the opposing surface thereof, and a pair of latching portions 514 standing on the flat plate portion 513. Cross-section].
- the latching portion 514 is latched on the side surface connecting the surface on the installation side and the opposing surface in order to dispose the flat plate portion 513 on the surface on the installation side of the inner core portion 31 and the opposing surface thereof.
- the latching portion 514 is configured to be provided only in part, not over the entire length of the flat plate portion 513. Absent.
- each of the divided pieces 511 and 512 uses a flat plate portion 513 provided with a window portion 515 penetrating the front and back.
- the peripheral wall portion 51 may be a cylindrical body disposed along the entire circumference of the outer peripheral surface of the inner core portion 31 (see FIG. 7 described later), but between the coil 2 and the inner core portion 31. If the insulation distance can be secured, a part of the inner core portion 31 may not be covered by the peripheral wall portion 51 as shown in FIG.
- the material of the insulator 5 can be reduced because a part of the inner core portion 31 is exposed from the peripheral wall portion 51. Further, when the sealing resin is provided, the inner core portion 31 can be divided into pieces 511, 512 having the window portion 515, or the entire periphery of the inner core portion 31 is not covered by the peripheral wall portion 51. In addition to increasing the contact area between the sealing resin and the sealing resin, bubbles are easily removed when the sealing resin is poured, and the reactor 1 is excellent in manufacturability.
- the inner surface of the flat plate portion 513 is in contact with the outer peripheral surface of the inner core portion 31, so that the plurality of core pieces 31m that are constituent elements of the inner core portion 31 can be aligned on the same plane.
- the insulator 5 has a pressing mechanism, which will be described later, so that a plurality of core pieces 31m constituting a surface on the installation side of the inner core portion 31 are divided into flat plates of divided pieces 512 arranged on the installation side in the peripheral wall portion 51. Alignment by the inner surface of the part 513 is possible.
- the outer surface of the flat plate portion 513 of the divided piece 512 is in contact with the inner peripheral surface of the coil 2 so that the turns of the coil 2 can be aligned on the same plane as described later.
- the flat plate portion 513 of the divided piece 512 is referred to as an installation surface portion.
- Each frame-like portion 52 is interposed between the end face of the coil 2 and the inner end face 32e of the outer core portion 32, and insulates the coil 2 from the outer core portion 32.
- Each frame-like part 52 has a flat plate-like main body part, and has a pair of openings 521 through which the respective inner core parts 31 are inserted.
- a short cylindrical portion that is continuous from the opening 521 of the main body portion and protrudes toward the inner core portion 31 is provided.
- the one frame-like portion 52 is provided with a pedestal 522 on which the coil connecting portion 2r is placed and insulates between the coil connecting portion 2r and the outer core portion 32.
- This pedestal 522 is a plate piece protruding in a bowl shape so as to be in contact with the surface facing the core installation surface 32d of the outer core portion 32 (upper surface in FIG. 5), and the peripheral wall portion when the reactor 1 is manufactured as described later It is also a part where a pressing member (not shown) directly contacts when 51 is pressed.
- the other frame-like portion 52 is provided with a protruding portion 523 that functions as a contact portion of the pressing member.
- the peripheral wall portion 51 and the frame-shaped portion 52 have an engaging portion that engages with each other.
- the flat plate portion 513 of each of the divided pieces 511, 512 has an engagement recess 516 at a location in contact with the frame-like portion 52, and the frame-like portion 52
- An engagement convex portion 526 is provided at a location where the cylindrical portion is in contact with the flat plate portion 513.
- the engaging concave portion 516 has a rectangular groove
- the engaging convex portion 526 has a simple shape such as a rectangular piece.
- the shape of the engaging portion is not particularly limited as long as the peripheral wall portion 51 and the frame-like portion 52 can be positioned with respect to each other, and it is necessary to have a complicated shape that is difficult to separate when the peripheral wall portion 51 and the frame-like portion 52 are engaged with each other.
- the shape can be easily separated by only engaging the engaging portion, for example, a polygonal shape such as a triangular shape or a curved shape such as a semicircular arc shape.
- the unevenness provided on the peripheral wall portion 51 and the frame-like portion 52 may be reversed.
- the engagement concave portion 516 and the engagement convex portion 526 it is allowed to have a certain gap between them.
- the insulator 5 is divided into the outer peripheral surface of the coil 2 that is arranged on the installation side in the peripheral wall portion 51 as described above in order to make the coil installation surface 2d in particular uniformly contact the heat radiation layer 42 described later.
- a pressing mechanism that presses the flat plate portion 513 (installation surface portion) of the piece 512 against the inner peripheral surface of the coil 2 is provided.
- each frame-like portion 52 has a protrusion 525 that presses the installation surface portion against the inner peripheral surface of the coil 2 when combined with the peripheral wall portion 51, and is pressed by the engagement portion and the protrusion 525. Configure functions. The pressing function will be described in detail in the manufacturing process of the reactor 1 described later.
- the protrusion 525 protrudes toward the peripheral wall 51 from the vicinity of the corner on the installation side (the lower side in FIGS. 3 to 5) of the tubular portion of the frame-like portion 52 in a state where the insulator 5 is assembled. It is a triangular piece. Then, one side of this small piece comes into contact with the installation surface portion so that the flat plate portion 513 (installation surface portion) of the split piece 512 is pressed against the inner peripheral surface of the coil 2 as shown in FIG. .
- the shape of the protrusion 525 is not particularly limited as long as the installation surface can be uniformly pressed against the inner periphery of the coil 2 in this way. As described above, it may be rectangular instead of triangular.
- the two projections 525 are provided in the vicinity of the two corners on the installation side of the two frame-like parts 52, that is, one installation surface part is pressed by the four projections 525.
- one installation surface part can be pressed stably and uniformly.
- Insulator 5 can be made of an insulating material such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, or liquid crystal polymer (LCP).
- PPS polyphenylene sulfide
- PTFE polytetrafluoroethylene
- PBT polybutylene terephthalate
- LCP liquid crystal polymer
- the case 4 in which the combined body 10 of the coil 2 and the magnetic core 3 is housed includes a flat bottom plate portion 40 and a frame-like side wall portion 41 standing on the bottom plate portion 40.
- the reactor 1 includes a bottom plate
- One of the features is that the portion 40 and the side wall portion 41 are not integrally molded and are fixed by a fixing material, and the bottom plate portion 40 is provided with a heat radiation layer 42.
- the bottom plate portion 40 is a rectangular plate, and is fixed to the fixed object when the reactor 1 is installed on the fixed object.
- the example shown in FIG. 2 shows an installation state in which the bottom plate portion 40 is downward, but there may be an installation state in which the bottom plate portion 40 is upward or sideward.
- the bottom plate portion 40 is formed with a heat radiation layer 42 on one surface arranged on the inner side.
- the outer shape of the bottom plate portion 40 can be selected as appropriate.
- the bottom plate portion 40 has mounting portions 400 protruding from the four corners, and the outer shape thereof is a shape along the outer shape of the side wall portion 41 described later, and the bottom plate portion 40 and the side wall portion 41 are combined.
- the mounting portion 400 overlaps the mounting portion 411 of the side wall portion 41.
- the attachment part 411 may not be provided on the side wall part 41, and the outer shape may be such that the attachment part 400 of the bottom plate part 40 protrudes from the outer shape of the side wall part 41.
- Each mounting portion 400 is provided with a bolt hole 400h through which a bolt (not shown) for fixing the case 4 to the fixing target is inserted.
- the bolt hole 400h is provided so as to be continuous with a bolt hole 411h of the side wall 41 described later.
- any of through holes that are not threaded and screw holes that are threaded can be used, and the number and the like can be appropriately selected.
- the side wall portion 41 is a rectangular frame-like body, and when the case 4 is assembled by closing one opening portion with the bottom plate portion 40, the side wall portion 41 is disposed so as to surround the assembly 10 and the other opening portion is opened.
- the side wall portion 41 has a rectangular shape along the outer shape of the bottom plate portion 40 when the reactor 1 is installed on a fixed object, and the open side region is magnetic with the coil 2. It is a curved surface shape along the outer peripheral surface of the combination 10 with the core 3.
- the outer peripheral surface of the coil 2 and the inner peripheral surface of the side wall 41 are close to each other, and the distance between the outer peripheral surface of the coil 2 and the inner peripheral surface of the side wall 41 is 0 mm to 1.0 mm.
- the region on the opening side of the side wall portion 41 is provided with a bowl-shaped portion arranged so as to cover the trapezoidal surface of the outer core portion 32 of the combined body 10, and is housed in the case 4
- the coil 2 is exposed as shown in FIG. 1, and the magnetic core 3 is substantially covered with the constituent material of the case 4.
- the hook-shaped part it is possible to improve vibration resistance, improve the rigidity of the case 4 (side wall part 41), and protect the assembly 10 from the external environment and mechanical protection.
- a portion covering the upper side of the one outer core portion 32 functions as a terminal block 410 to which the terminal fitting 8 is fixed.
- the terminal fitting 8 connects the welding surface 81 connected to the end of the winding 2w constituting the coil 2, the connection surface 82 for connecting to an external device such as a power source, and the welding surface 81 and the connection surface 82. It is a rectangular plate member having a connecting portion, and is bent into an appropriate shape as shown in FIG. In addition to welding such as TIG welding, crimping or the like can be used to connect the conductor portion of the winding 2w and the terminal fitting 8.
- the shape of the terminal fitting 8 is an example, and an appropriate shape can be used.
- the terminal block 410 is formed with a concave groove 410c in which the connecting portion of the terminal fitting 8 is disposed.
- the terminal metal fitting 8 fitted in the concave groove 410c is covered with a terminal fixing member 9 above, and is fixed to the terminal block 410 by tightening the terminal fixing member 9 with a bolt 91.
- a terminal fixing member 9 As the constituent material of the terminal fixing member 9, an insulating material such as an insulating resin used for the constituent material of the case described later can be suitably used.
- a terminal block can be made into another member, for example, it can be set as the form which fixes a terminal block to a side wall part separately.
- a side wall part, a terminal metal fitting, and a terminal stand part can also be made into the integrated form by insert-molding a terminal metal fitting.
- the region on the installation side of the side wall portion 41 includes mounting portions 411 protruding from the four corners, and each mounting portion 411 is provided with a bolt hole 411h.
- the bolt hole 411h may be formed only from the constituent material of the side wall portion 41, or may be formed by arranging a cylindrical body made of another material.
- the cylindrical body is excellent in strength when using a metal tube made of a metal such as brass, steel, stainless steel, etc., so that creep deformation of the resin is suppressed. Can do.
- a metal tube is arranged to form the bolt hole 411h.
- the constituent material of the case 4 is, for example, a metal material
- the metal material generally has a high thermal conductivity, so that the case can have excellent heat dissipation.
- Specific metals include, for example, aluminum and its alloys, magnesium (thermal conductivity: 156 W / m ⁇ K) and its alloys, copper (390 W / m ⁇ K) and its alloys, silver (427 W / m ⁇ K) and Examples thereof include iron, austenitic stainless steel (for example, SUS304: 16.7 W / m ⁇ K).
- the aluminum, magnesium, and alloys thereof are used, a lightweight case can be obtained, which can contribute to reducing the weight of the reactor.
- aluminum and its alloys are excellent in corrosion resistance and can be suitably used for in-vehicle components.
- the case 4 is formed of a metal material, it can be formed by plastic working such as press working in addition to casting such as die casting.
- the constituent material of the case 4 is a non-metallic material such as polybutylene terephthalate (PBT) resin, urethane resin, polyphenylene sulfide (PPS) resin, acrylonitrile-butadiene-styrene (ABS) resin, or the like. Since many materials are generally excellent in electrical insulation, the insulation between the coil 2 and the case 4 can be enhanced. Further, these non-metallic materials are lighter than the above-described metallic materials, and the reactor 1 can be made light. When the resin is mixed with a filler made of ceramic described later, the heat dissipation can be improved. When the case 4 is formed of resin, injection molding can be suitably used.
- PBT polybutylene terephthalate
- PPS polyphenylene sulfide
- ABS acrylonitrile-butadiene-styrene
- the constituent material of the bottom plate portion 40 and the side wall portion 41 can be the same material. In this case, both thermal conductivity becomes equal. Or since the baseplate part 40 and the side wall part 41 are separate members, both constituent materials can be varied. In this case, in particular, when both constituent materials are selected so that the thermal conductivity of the bottom plate portion 40 is larger than the thermal conductivity of the side wall portion 41, the heat of the coil 2 and the magnetic core 3 disposed on the bottom plate portion 40 is selected. Can be efficiently discharged to a fixed object such as a cooling base.
- the bottom plate portion 40 is made of aluminum
- the side wall portion 41 is made of PBT resin.
- Various fixing materials can be used as a method of integrally connecting the bottom plate portion 40 and the side wall portion 41.
- the fixing material include fastening members such as adhesives and bolts.
- a bolt hole (not shown) is provided in the bottom plate portion 40 and the side wall portion 41, a bolt (not shown) is used as a fixing member, and the bolts are screwed together to integrate them.
- a heat radiation layer 42 is provided at a location where the coil installation surface 2d (FIG. 5) of the coil 2 and the core installation surface 32d (FIG. 5) of the outer core portion 32 contact each other.
- the heat radiation layer 42 is made of an insulating material having a thermal conductivity of more than 2 W / m ⁇ K.
- the heat dissipation layer 42 preferably has a higher thermal conductivity, and is composed of a material of 3 W / m ⁇ K or higher, particularly 10 W / m ⁇ K or higher, more preferably 20 W / m ⁇ K or higher, especially 30 W / m ⁇ K or higher. Is preferred.
- the constituent material of the heat dissipation layer 42 include non-metallic inorganic materials such as ceramics such as a kind of material selected from metal elements, B, and Si oxides, carbides, and nitrides. More specific ceramics are silicon nitride (Si3N4): 20W / m ⁇ K to 150W / m ⁇ K, alumina (Al2O3): 20W / m ⁇ K to 30W / m ⁇ K, aluminum nitride (AlN): 200W / m ⁇ K to 250W / m ⁇ K, Boron nitride (BN): 50W / m ⁇ K to 65W / m ⁇ K, Silicon carbide (SiC): 50W / m ⁇ K to 130W / m ⁇ K Degree etc.
- Si3N4 silicon nitride
- Al2O3 aluminum nitride
- AlN aluminum nitride
- the heat dissipation layer 42 is formed from the ceramics, for example, a vapor deposition method such as a PVD method or a CVD method can be used.
- the heat-dissipating layer 42 can also be formed by preparing a ceramic sintered plate or the like and bonding it to the bottom plate portion 40 with an appropriate adhesive.
- the constituent material of the heat dissipation layer 42 may be an insulating resin containing a filler made of the above ceramics.
- the insulating resin include an epoxy resin and an acrylic resin.
- the heat dissipation layer 42 having excellent heat dissipation and electrical insulation can be formed.
- the heat dissipation layer 42 can be easily formed by applying the resin to the bottom plate portion 40 or the like.
- the heat radiation layer 42 is made of an insulating resin, it is particularly preferable to use an adhesive because the adhesion between the coil 2 and the heat radiation layer 42 can be improved.
- the heat dissipation layer 42 is formed from the insulating resin, it can be easily formed by using, for example, screen printing.
- the heat radiation layer 42 is formed of an epoxy adhesive containing a filler made of alumina (thermal conductivity: 3 W / m ⁇ K).
- the heat dissipation layer 42 is formed of a two-layer structure of the adhesive layer, and the thickness of one layer is 0.2 mm, for a total of 0.4 mm.
- the heat dissipating layer 42 may have three or more layers, and in the case of such a multilayer structure, at least one layer of materials may be different.
- a layer in contact with the coil 2 or the bottom plate portion 40 can be made more excellent in adhesiveness, and the other layers can be made more excellent in heat dissipation.
- the shape of the heat dissipation layer 42 is not particularly limited as long as the coil installation surface 2d and the core installation surface 32d have an area that can sufficiently contact the heat dissipation layer 42.
- the heat radiation layer 42 has a shape along the shape formed by the coil installation surface 2d of the coil 2 and the core installation surface 32d of the outer core portion 32.
- the case 4 may be filled with a sealing resin (not shown) made of an insulating resin.
- a sealing resin (not shown) made of an insulating resin.
- the sealing resin include an epoxy resin, a urethane resin, and a silicone resin.
- the sealing resin contains a filler excellent in insulation and thermal conductivity, for example, a filler made of at least one ceramic selected from silicon nitride, alumina, aluminum nitride, boron nitride, mullite, and silicon carbide. Then, the heat dissipation can be further enhanced.
- the packing 6 When the sealing resin is filled in the case 4, in order to prevent uncured resin from leaking through the gap between the bottom plate portion 40 and the side wall portion 41, the packing 6 may be disposed.
- the packing 6 is an annular body having a size that can be fitted to the outer periphery of the combined body 10 of the coil 2 and the magnetic core 3, and is made of a synthetic rubber. Material can be used.
- the reactor 1 having the above-described configuration can be manufactured as follows.
- the combined body 10 of the coil 2 and the magnetic core 3 is formed. Specifically, as shown in FIG. 3 (B), the core piece 31m and the gap material 31g are laminated to form the inner core part 31, and the peripheral wall part 51 (divided pieces 511, 512) of the insulator 5 is disposed on the outer periphery. In this state, the coil elements 2a and 2b are inserted. At this time, the peripheral wall portion 51 includes the latching portion 514, so that it can be easily disposed on the surface on the installation side of the inner core portion 31 and the opposite surface.
- the frame-shaped portion 52 and the outer core portion 32 are placed on the coil 2 so that the end surfaces of both the coil elements 2a and 2b and the end surface 31e of the inner core portion 31 are sandwiched between the frame-shaped portion 52 of the insulator 5 and the inner end surface 32e of the outer core portion 32.
- the end surface 31e of the inner core portion 31 is exposed from the opening of the frame-shaped portion 52 and contacts the inner end surface 32e of the outer core portion 32.
- the cylindrical part of the frame-like part 52 can be used as a guide. Further, by engaging the engagement concave portion 516 of the peripheral wall portion 51 with the engagement convex portion 526 of the frame-like portion 52, the mutual position of the peripheral wall portion 51 and the frame-like portion 52 can be adjusted appropriately.
- the core piece 31m and the gap material 31g can be joined and integrated by, for example, applying an adhesive or winding an adhesive tape.
- the adhesive is not used.
- the pair of divided pieces 511 and 512 constituting the peripheral wall portion 51 are not configured to be engaged with each other, but are engaged with the frame-like portion 52 as described above and together with the inner core portion 31 in the coil elements 2a and 2b.
- the outer core portion 32 is further disposed, so that the state of being disposed between the inner peripheral surfaces of the coil elements 2a and 2b and the inner core portion 31 is maintained and does not fall off.
- an aluminum plate is punched into a predetermined shape to form a bottom plate portion 40, and a heat radiation layer 42 having a predetermined shape is formed on one surface by screen printing. On this heat radiation layer 42, the assembled body 10 assembled as described above is bonded and fixed.
- both the outer core portions 32 are held so as to sandwich the inner core portion 31 of the combined body 10, and the outer core portion 32 is opposed to the core installation surface 32d (
- the upper surface in FIG. 5 and the pedestal 522 and the projecting portion 523 of both frame-shaped parts 52 of the insulator 5 are pressed toward the heat radiation layer 42 (downward in FIG. 5) as indicated by the white arrow.
- the projection 525 of the frame-like portion 52 presses the flat plate portion 513 (installation surface portion) of the split piece 512 on the installation side toward the heat radiation layer.
- the installation surface portion is uniformly pressed toward the heat dissipation layer 42, and the installation surface portion of the coil 2
- the inner peripheral surface is also pressed uniformly.
- an appropriate pressing member (not shown) can be used, and the pressing force is set such that the magnetic core 3, the insulator 5, the insulating coating of the coil 2, the heat radiation layer 42, and the like are not damaged.
- a slight gap is provided between the installation side portion of the frame-like portion 52 of the insulator 5 and the heat radiation layer 42.
- the frame-like portion 52 When the size of the frame-like portion 52 and the size of the opening are adjusted so that a gap is provided, when the frame-like portion 52 is pressed toward the heat dissipation layer 42 as described above, the base 522 and the protruding portion 523 The frame-like portion 52 can ensure a sufficient movement allowance until the outer core portion 32 comes into contact with the surface facing the core installation surface 32d.
- the inner peripheral surface of the coil 2 is uniformly pressed, i.e., pressed so as to be a flat surface, so that the turns constituting the coil installation surface 2d are aligned among the outer peripheral surfaces of the coil 2.
- The As a result, a shape error or the like caused when the coil 2 is wound is corrected, and the coil installation surface 2d is likely to be a smooth surface.
- the outer dimension of the coil 2 is substantially the same as the design dimension, and therefore the coil installation surface 2d is configured by a substantially flat surface and the outer core portion 32 It is substantially flush with the core installation surface 32d.
- the coil installation surface 2d of the coil 2 has a concavo-convex shape corresponding to the error, and a portion protruding from the core installation surface 32d of the outer core portion 32 may occur.
- the winding 2w in consideration of the dimensional error in the thickness of the insulating coating so that the amount of protrusion is less than the thickness of the heat dissipation layer 42, the above-mentioned protruding portion is removed from the adhesive by the above pressing. It can be embedded in the heat dissipation layer 42.
- the heat radiation layer 42 by configuring the heat radiation layer 42 with an insulating adhesive, it is possible to absorb the error of the winding 2w depending on the thickness. As described above, the insulation between the coil 2 and the case 4 can be sufficiently secured by appropriately selecting the thickness of the insulation coating of the winding 2w and the thickness of the heat dissipation layer 42.
- the assembly 10 can be firmly fixed to the bottom plate portion 40 by the heat dissipation layer 42 being configured by an adhesive and the coil installation surface 2d of the coil 2 being pressed against the heat dissipation layer 42 in an aligned state by the insulator 5. .
- the outer core portion 32 can also be firmly fixed to the heat dissipation layer.
- the packing 6 is disposed on the outer periphery of the combined body 10.
- an adhesive can be used for joining the core piece 31m and the gap material 31g.
- the core piece 31m coated with an adhesive and the gap material 31g are laminated and the inner core portion 31 is assembled, and then the peripheral wall portion 51 and the coil 2 are arranged as described above.
- the frame-like portion 52 is disposed between the coil 2 and the outer core portion 32 as described above, and the end surface 31e of the inner core portion 31 coated with the adhesive and the inner end surface 32e of the outer core portion 32 are brought into contact with each other.
- Form a union 10 may be used to make the coil installation surface smooth and to cure the adhesive.
- a fixing jig 100 shown in FIG. 6 is arranged so as to be slidable on the plate-like main body 101 on which the combined body 10 is placed and sandwiches both outer core portions 32 of the combined body 10.
- a pair of core pressing portions 102 arranged, a pair of insulator pressing portions 103 that press each frame-like portion of the insulator, and a support portion 104 that slidably supports each insulator pressing portion 103 with respect to the main body 101 are provided.
- Each core pressing portion 102 is connected to the main body 101 by a bolt 105, and when the bolt 105 is tightened, the core pressing portion 102 slides close to each other and can press both outer core portions 32 in a direction close to each other.
- Each insulator pressing portion 103 is a plate piece arranged along each frame-like portion, arranged so as to cross a pair of support portions 104 arranged so as to sandwich the pair of coil elements 2a, 2b, and bolts It is connected to the support part 104 by 106. Then, by tightening the bolt 106, the insulator pressing portion 103 can press the frame-shaped portion toward the main body 101 (downward in FIG. 6).
- the combined body 10 in which the coil 2 and the magnetic core 3 are assembled as described above is placed on the main body 101, the core pressing part 102 is slid, and the combined body 10 is clamped by the core pressing part 102. Further, the support portion 104 is slid to arrange each insulator pressing portion 103 at the position of the frame-shaped portion of the combined body 10. Then, the bolt 105 is tightened and both outer core portions 32 are pressed by the core pressing portion 102, and the bolt 106 is tightened and the frame pressing portion is pressed by the insulator pressing portion 103.
- the outer core portions 32 it is easy to make the thickness of the adhesive uniform, and by pressing the frame-shaped portion, the coil installation surface can be made smooth with few irregularities as described above.
- the coil installation surface and the core installation surface of the outer core portion 32 can be flush with each other.
- the adhesive may be cured. By doing so, it is possible to form a combined body 10 integrated with an adhesive and having a smooth coil installation surface. By bringing such a combined body 10 into contact with the heat radiating layer, the combined body 10 (particularly the coil 2) can be firmly fixed to the heat radiating layer as in the case where the above-described adhesive is not used.
- the side wall portion 41 configured in a predetermined shape by injection molding or the like is covered from the upper side of the combined body 10 so as to cover the outer peripheral surface of the combined body 10, and the bottom plate portion 40 is provided by separately prepared bolts (not shown). And the side wall 41 are integrated.
- the combined body 10 is configured such that one of the trapezoidal surfaces of each outer core portion 32 is covered by the terminal block 410 and the above-described hook-shaped portion, and the side wall portion 41 is attached to the combined body 10. It is possible to prevent the combined body 10 from dropping from the side wall portion 41 when positioning or installing the reactor 1 so that the bottom plate portion 40 is upward or sideward.
- a position fixing portion for preventing the outer core portion 32 from falling off may be separately provided inside the terminal block 410 or the bowl-shaped portion.
- the welding surface 81 of the terminal fitting 8 is welded to the end of the winding 2w protruding from the case 4, and the terminal fitting 8 is fitted into the concave groove 410c (FIG. 2) of the terminal block 410 (FIG. 2) of the side wall 41. .
- the terminal fixture 8 is fixed to the terminal block 410 by covering the connecting portion of the terminal fitting 8 with the terminal fixing member 9 and fixing the terminal fixing member 9 to the side wall portion 41 with the bolts 91. By this step, the reactor 1 without the sealing resin is formed.
- the reactor 1 including the sealing resin is formed by filling the case 4 with a sealing resin (not shown) and curing it.
- the terminal fitting 8 may be fixed to the terminal block 410 with the bolt 91, and after filling the sealing resin, the end of the winding 2w and the welding surface 81 of the terminal fitting 8 may be welded.
- ⁇ Usage ⁇ Reactor 1 having the above-described configuration has applications where the energization conditions are, for example, maximum current (DC): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, and operating frequency: about 5 kHz to 100 kHz, typically electric It can be suitably used as a component part of an in-vehicle power converter such as an automobile or a hybrid automobile.
- DC maximum current
- ⁇ Effect ⁇ Reactor 1 having the above configuration is a coil generated during use by interposing a heat dissipation layer 42 having a thermal conductivity of more than 2 W / m ⁇ K and excellent thermal conductivity between bottom plate portion 40 and coil 2.
- the heat of 2 and the heat of the magnetic core 3 can be efficiently released to a fixed object such as a cooling base through the heat dissipation layer. Therefore, the reactor 1 is excellent in heat dissipation.
- the bottom plate portion 40 is made of a material having excellent thermal conductivity such as aluminum, the heat from the heat radiation layer 42 can be efficiently released to the fixing target, and the heat dissipation is excellent.
- the bottom plate portion 40 is made of a metal material (conductive material)
- the heat radiation layer 42 is made of an insulating adhesive, the coil 2 can be formed even if it is as thin as 0.4 mm. Insulation between the base plate 40 and the bottom plate portion 40 can be ensured. Since the heat dissipation layer 42 is thin as described above, the heat of the coil 2 and the like can be easily transmitted to the fixed object through the bottom plate portion 40, and the reactor 1 is excellent in heat dissipation.
- the heat dissipation layer 42 is composed of an insulating adhesive, it has excellent adhesion between the coil 2 and the magnetic core 3 and the heat dissipation layer 42, so it is easy to transfer heat from the coil 2 etc. to the heat dissipation layer 42, Reactor 1 has excellent heat dissipation.
- the reactor 1 includes an insulator 5 having a pressing function, and by this pressing function, the turns constituting the coil installation surface 2d, in particular, of the outer peripheral surface of the coil 2 are aligned to dissipate heat on the coil installation surface 2d. A sufficient contact area with the layer 42 can be ensured. Also from this, the heat of the coil 2 can be efficiently released to the heat dissipation layer 42, and the reactor 1 is excellent in heat dissipation. In particular, by using a covered rectangular wire as the winding 2w, the entire side surface portion of each turn constituting the coil installation surface 2d can be uniformly contacted with the heat dissipation layer 42. From this point, the reactor 1 is excellent in heat dissipation. Furthermore, by providing the insulator 5, the reactor 1 can enhance the insulation between the coil 2 and the magnetic core 3.
- the reactor 1 includes the case 4, it is possible to protect the union 10 from the environment and mechanical protection.
- the reactor 1 is light in weight because the side wall 41 is made of resin, and the distance between the outer peripheral surface of the coil 2 and the inner peripheral surface of the side wall 41 is reduced. Therefore, it is small.
- the heat dissipation layer 42 is thin as described above, the distance between the coil installation surface 2d of the coil 2 and the inner surface of the bottom plate portion 40 can be reduced, and thus the reactor 1 is small.
- the reactor 1 has a configuration in which the bottom plate portion 40 and the side wall portion 41 are separate members and are combined and integrated, the heat radiation layer 42 can be formed on the bottom plate portion 40 with the side wall portion 41 removed. Therefore, the reactor 1 can easily form the heat dissipation layer 42 and is excellent in productivity. Further, when the assembly 10 is joined to the bottom plate portion 40 including the heat radiation layer 42, the side wall portion 41 can be removed, so that the above-described pressing and the like are easily performed, and the productivity is excellent. Furthermore, since the bottom plate portion 40 and the side wall portion 41 are separate members, the respective materials can be made different, so that the range of selection of constituent materials can be widened.
- the space between the coil installation surface of the coil and the inner surface of the bottom plate portion can be reduced by providing the heat dissipation layer made of an insulating material, so that the size is small.
- an interval for ensuring insulation is provided between the outer peripheral surface of the coil and the inner surface of the side wall.
- the heat dissipation layer is configured by the insulating adhesive
- the heat dissipation layer may be configured by ceramics such as aluminum nitride and alumina.
- each peripheral wall portion 51 of the insulator 5 is configured by the pair of divided pieces 511 and 512 has been described.
- the peripheral wall portion 51 ⁇ can be formed as one cylindrical body.
- the insulator 5 ⁇ will be described in detail, and the other configuration is the same as that of the above-described embodiment, and thus description thereof will be omitted.
- the insulator 5 ⁇ includes a pair of cylindrical peripheral wall portions 51 ⁇ in which the inner core portion 31 of the magnetic core 3 is accommodated, and a pair of frame-like portions 52 ⁇ that are in contact with the inner core portion 31 and the outer core portion 32. Similar to the embodiment, the peripheral wall portion 51 ⁇ and the frame-like portion 52 ⁇ have engaging portions (fitting irregularities 516 ⁇ and 526 ⁇ ) that engage with each other.
- Each peripheral wall portion 51 ⁇ is a rectangular tubular body along the outer shape of the inner core portion 31, and the installation surface side (the back side in the drawing in FIG. 7) is configured in a flat plate shape, and this flat plate portion serves as the installation surface portion. .
- a fitting uneven portion 516 ⁇ to which the fitting uneven portion 526 ⁇ of the frame-like portion 52 ⁇ is fitted is provided at the end of the peripheral wall portion 51 ⁇ .
- Each frame-like portion 52 ⁇ has a pair of openings 521 through which each inner core portion 31 is inserted in a flat plate-like main body portion like the frame-like portion 52 of the embodiment.
- a fitting uneven portion 526 ⁇ is provided on the side in contact with the peripheral wall portion 51 ⁇ similarly to the peripheral wall portion 51 ⁇ , and the outer core portion 32 is positioned on the side in contact with the outer core portion 32.
- -Shaped frame portion 527 is provided.
- a part of the frame portion 527 functions as a base 522 and a protruding portion 523 in the same manner as the insulator 5 of the embodiment.
- the fitting uneven portion 516 ⁇ of the peripheral wall portion 51 ⁇ and the fitting uneven portion 526 ⁇ of the frame-like portion 52 ⁇ are fitted to each other, so that the position of each other can be maintained.
- the outer core portion 32 is placed with the inner end face of one outer core portion 32 facing upward in FIG. 7, and one frame-like portion 52 ⁇ is slid from the opening side of the frame portion 527 to place the frame portion 527 is fitted into the outer core portion 32.
- one outer core portion 32 is positioned with respect to one frame-shaped portion 52 ⁇ .
- the fitting uneven portion 516 ⁇ of the peripheral wall portion 51 ⁇ is fitted to the fitting uneven portion 526 ⁇ of the one frame-like portion 52 ⁇ , and the pair of peripheral wall portions 51 ⁇ are attached to the frame-like portion 52 ⁇ .
- the positional relationship between the one frame-shaped portion 52 ⁇ and the peripheral wall portion 51 ⁇ is maintained.
- the core pieces 31m and the gap material 31g are alternately inserted and laminated on the peripheral wall portion 51 ⁇ .
- the laminated inner core portion 31 is held in the laminated state by the peripheral wall portion 51 ⁇ .
- the peripheral wall portion 51 ⁇ has a shape having slits opened upward in a pair of side surfaces thereof, the core piece 31m is designated when the core piece 31m and the gap material 31g are inserted into the peripheral wall portion 51 ⁇ . Therefore, the insertion operation can be performed safely and easily.
- the coil coupling part side of a coil (not shown) is faced down in FIG. 7, and both coil elements are mounted on the outer periphery of the peripheral wall part 51 ⁇ .
- the other frame-like portion 52 ⁇ is attached to the peripheral wall portion 51 ⁇
- the other outer core portion 32 is attached to the other frame-like portion 52 ⁇ in the same manner as described above.
- the positional relationship between the peripheral wall portion 51 ⁇ and the other frame-shaped portion 52 ⁇ is maintained, and the other outer core portion 32 is positioned with respect to the other frame-shaped portion 52 ⁇ .
- ⁇ / RTI> Arrange the assembly so that one of the trapezoidal surfaces of the outer core portions 32 is in contact with the heat dissipation layer of the bottom plate portion so that the assembly is tilted from the state shown in FIG. Then, as described in the embodiment, the pedestal 522, the protruding portion 523, and the outer core portion 32 of the frame-shaped portion 52 ⁇ are pressed toward the heat dissipation layer. At this time, by engaging the fitting uneven portions 516 ⁇ and 526 ⁇ , the frame-shaped portion 52 ⁇ is pressed, so that the peripheral wall portion 51 ⁇ is also pressed, and the flat installation surface portion of the peripheral wall portion 51 ⁇ is the coil as in the embodiment. Press the inner surface. As a result, the turns forming the coil installation surface of the coil are aligned.
- the insulator 5 ⁇ By using the insulator 5 ⁇ , it is possible to adopt a configuration in which no adhesive is used in forming the magnetic core 3 as in the above-described embodiment.
- the insulator 5 ⁇ is easy to maintain an integrated state by engagement of the peripheral wall portion 51 ⁇ and the frame-shaped portion 52 ⁇ , and is easy to handle when the assembly is disposed on the bottom plate portion of the case.
- the insulator 5 ⁇ can use a part of the engaging portion (the fitting uneven portions 516 ⁇ and 526 ⁇ ) as a pressing function of the installation surface portion in the same manner as the protruding portion 525 of the embodiment.
- the back surface of one outer core portion 32 is brought into contact with the side wall portion of the case, and the other outer core portion 32 is placed on the one outer core portion 32 side between the back surface and the side wall portion of the other outer core portion 32.
- the member to be pressed for example, a leaf spring
- the gap length can be prevented from changing due to external factors such as vibration and impact.
- the gap material 31g is an elastic gap material made of an elastic material such as silicone rubber or fluororubber
- the gap length can be adjusted by changing the gap material 31g, Dimensional errors can be absorbed.
- the pressing member and the elastic gap material can also be used for the above-described embodiments, modified examples, and modified examples described later.
- a belt-like fastening material (not shown) that can hold the magnetic core in an annular shape
- the belt-like fastening material include a belt portion arranged on the outer periphery of the magnetic core and a lock portion that is attached to one end of the belt portion and fixes a loop formed by the belt portion to a predetermined length. It is done.
- the lock portion include those having an insertion hole through which the other end side region of the band portion having the protrusion is inserted, and a tooth portion provided in the insertion hole and biting into the protrusion of the band portion. And what can fix the loop of the said predetermined
- prescribed length can be utilized suitably because the protrusion of the other end side area
- the material of the belt-shaped fastening material is non-magnetic and has heat resistance that can withstand the temperature when the reactor is used, for example, metal material such as stainless steel, heat resistant polyamide resin, polyether ether ketone (PEEK) resin
- metal material such as stainless steel, heat resistant polyamide resin, polyether ether ketone (PEEK) resin
- PEEK polyether ether ketone
- Non-metallic materials such as polyethylene terephthalate (PET) resin, polytetrafluoroethylene (PTFE) resin, and polyphenylene sulfide (PPS) resin.
- Commercially available binding materials such as tie wrap (registered trademark of Thomas and Bets International Inc.), peak tie (binding band manufactured by Heraman Taiton Co., Ltd.), and stainless steel band (manufactured by Pound Wit Corporation) may be used.
- the band portion is, for example, the outer periphery of one outer core portion, between the outer periphery of one inner core portion and the inner peripheral surface of the coil element, and the other outer core portion.
- the magnetic core can be fixed in an annular shape by turning between the outer periphery of the inner core portion and the outer periphery of the other inner core portion and the inner peripheral surface of the coil element and fixing the loop length with the lock portion.
- zone part can be arrange
- the magnetic core can be integrated without using an adhesive.
- the assembly is easy to handle.
- a buffer material is interposed between the outer periphery of the magnetic core or the outer periphery of the coil and the belt-like fastening material, it is possible to suppress damage to the magnetic core or the coil due to the fastening force of the belt-like fastening material.
- the material, thickness, number, location, and the like of the buffer material can be appropriately selected so that a tightening force that allows the annular magnetic core to maintain a predetermined shape acts on the magnetic core.
- the reactor of the present invention can be suitably used for a component part of a power conversion device such as an in-vehicle converter mounted on a vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle.
- a power conversion device such as an in-vehicle converter mounted on a vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle.
Abstract
Description
放熱層の形成工程:上記ケースの底板部の内面に、熱伝導率が2W/m・K超の絶縁性材料からなる放熱層を形成する工程。
コイルの押付工程:上記コイルと上記磁性コアとの間に両者を絶縁するインシュレータを配置し、このインシュレータにより上記コイルを上記放熱層に押し付けて、上記コイルを上記放熱層に均一的に接触させる工程。
ケースの組立工程:上記底板部に固定材により上記側壁部を取り付けて、上記ケースを形成する工程。
なお、コイルの押付工程とケースの組立工程とはいずれを先に行ってもよい。
リアクトル1は、コイル2とコイル2が配置される磁性コア3との組合体10と、組合体10を収納するケース4とを具える。ケース4は、一面が開口した箱体であり、代表的には封止樹脂(図示せず)が充填され、組合体10は、コイル2を形成する巻線2wの端部を除いて封止樹脂に埋設される。また、組合体10は、コイル2と磁性コア3との間を絶縁するインシュレータ5を具える。リアクトル1の特徴とするところは、ケース4が分割可能な構成であること、及びインシュレータ5の形状にある。以下、各構成部材をより詳細に説明する。
[コイル]
コイル2は、図2,図3を適宜参照して説明する。コイル2は、接合部の無い1本の連続する巻線2wを螺旋状に巻回してなる一対のコイル素子2a,2bと、両コイル素子2a,2bを連結するコイル連結部2rとを具える。各コイル素子2a,2bは、互いに同一の巻数で、軸方向から見た形状(端面形状)がほぼ矩形状(角部を丸めた長方形状)である。これら両コイル素子2a,2bは、各軸方向が平行するように横並びに並列されており、コイル2の他端側(図2では紙面奥側)において巻線2wの一部がU字状に屈曲されてコイル連結部2rが形成されている。この構成により、両コイル素子2a,2bの巻回方向は同一となっている。
磁性コア3の説明は、図3,図5を適宜参照して行う。磁性コア3は、各コイル素子2a,2bがそれぞれ配置される一対の内側コア部31と、コイル2が配置されず、コイル2から露出されている一対の外側コア部32とを有する。ここでは、各内側コア部31はそれぞれ直方体状であり(ここでは角部を丸めている)、各外側コア部32はそれぞれ、一対の台形状面を有する角柱状体である。磁性コア3は、離間して配置される内側コア部31を挟むように外側コア部32が配置され、各内側コア部31の端面31eと外側コア部32の内端面32eとを接触させて環状に形成される。これら内側コア部31及び外側コア部32により、コイル2を励磁したとき、閉磁路を形成する。
インシュレータの説明は、図3~図5を適宜参照して行う。組合体10は、コイル2と磁性コア3との間にインシュレータ5を具えて、コイル2と磁性コア3との間の絶縁性を高めている。インシュレータ5は、内側コア部31の外周に配置される周壁部51と、コイル2の端面(コイル素子のターンが環状に見える面)に当接される一対の枠状部52とを具えた構成が挙げられる。なお、わかり易いように、図4(A)では、一方の内側コア部に配置される周壁部51を省略し、図4(B)では、一方の周壁部51の近傍のみを示す。
ケース4の説明は、図2を適宜参照して行う。上記コイル2と磁性コア3との組合体10が収納されるケース4は、平板状の底板部40と、底板部40に立設する枠状の側壁部41とを具え、リアクトル1は、底板部40と側壁部41とが一体に成形されておらず、固定材により固定される点、底板部40に放熱層42を具える点を特徴の一つとする。
(底板部)
底板部40は、矩形状板であり、リアクトル1が固定対象に設置されるときに固定対象に固定される。図2に示す例では、底板部40が下方となる設置状態を示すが、底板部40が上方、或いは側方となる設置状態も有り得る。この底板部40は、ケース4を組み立てたとき、内側に配置される一面に放熱層42が形成されている。底板部40の外形は適宜選択することができる。ここでは、底板部40は、四隅のそれぞれから突出した取付部400を有しており、その外形は後述する側壁部41の外形に沿った形状としており、底板部40と側壁部41とを組み合せてケース4を形成した場合、この取付部400は、側壁部41の取付部411と重なる。その他、側壁部41に取付部411を設けず、底板部40の取付部400が側壁部41の外形から突出するような外形としてもよい。各取付部400にはそれぞれ、固定対象にケース4を固定するボルト(図示せず)が挿通されるボルト孔400hが設けられている。ボルト孔400hは、後述する側壁部41のボルト孔411hに連続するように設けられている。ボルト孔400h,411hは、ネジ加工が成されていない貫通孔、ネジ加工がされたネジ孔のいずれも利用でき、個数なども適宜選択することができる。
側壁部41は、矩形枠状体であり、一方の開口部を底板部40により塞いでケース4を組み立てたとき、上記組合体10の周囲を囲むように配置され、他方の開口部が開放される。ここでは、側壁部41は、リアクトル1を固定対象に設置したときに設置側となる領域が上記底板部40の外形に沿った矩形状であり、開放された開口側の領域がコイル2と磁性コア3との組合体10の外周面に沿った曲面形状である。ケース4を組み立てた状態において、コイル2の外周面と側壁部41の内周面とは近接しており、コイル2の外周面と側壁部41の内周面との間隔は、0mm~1.0mm程度と非常に狭い。また、ここでは、側壁部41の開口側の領域には、組合体10の外側コア部32の台形状面を覆うように配置される庇状部が設けられており、ケース4に収納された組合体10は、図1に示すようにコイル2が露出され、磁性コア3は実質的にケース4の構成材料に覆われる。上記庇状部を具えることで、耐振動性の向上、ケース4(側壁部41)の剛性の向上、その他、組合体10の外部環境からの保護や機械的保護を図ることができる。なお、上記庇状部を省略して、コイル2と共に、両外側コア部32の一方の台形状面がいずれも露出される形態としてもよい。
上記側壁部41の開口側の領域において、一方の外側コア部32の上方を覆う箇所は、端子金具8が固定される端子台410として機能する。
側壁部41の設置側の領域は、底板部40と同様に、四隅のそれぞれから突出する取付部411を具え、各取付部411には、ボルト孔411hが設けられている。ボルト孔411hは、側壁部41の構成材料のみにより形成してもよいし、別材料からなる筒体を配置させて形成してもよい。例えば、側壁部41を樹脂により構成する場合、上記筒体は、例えば、真鍮、鋼、ステンレス鋼などの金属からなる金属管を利用すると、強度に優れることから、樹脂のクリープ変形を抑制することができる。ここでは、金属管を配置してボルト孔411hを形成している。
ケース4の構成材料は、例えば、金属材料とすると、金属材料は一般に熱伝導率が高いことから、放熱性に優れたケースとすることができる。具体的な金属は、例えば、アルミニウムやその合金、マグネシウム(熱伝導率:156W/m・K)やその合金、銅(390W/m・K)やその合金、銀(427W/m・K)やその合金、鉄やオーステナイト系ステンレス鋼(例えば、SUS304:16.7W/m・K)が挙げられる。上記アルミニウムやマグネシウム、及びその合金を利用すると、軽量なケースとすることができ、リアクトルの軽量化に寄与することができる。特に、アルミニウムやその合金は、耐食性にも優れるため、車載部品に好適に利用することができる。金属材料によりケース4を形成する場合、ダイキャストといった鋳造の他、プレス加工などの塑性加工により形成することができる。
底板部40と側壁部41とを一体に接続する手法は、種々の固定材を利用することができる。固定材は、例えば、接着剤やボルトといった締結部材が挙げられる。ここでは、底板部40及び側壁部41にボルト孔(図示せず)を設け、固定材にボルト(図示せず)を利用し、このボルトをねじ込むことで、両者を一体化している。
底板部40において、コイル2のコイル設置面2d(図5)及び外側コア部32のコア設置面32d(図5)が接触する箇所に放熱層42を具える。放熱層42は、熱伝導率が2W/m・K超の絶縁性材料により構成されている。放熱層42は、熱伝導率が高いほど好ましく、3W/m・K以上、特に10W/m・K以上、更に20W/m・K以上、とりわけ30W/m・K以上の材料により構成されることが好ましい。
ケース4内に絶縁性樹脂からなる封止樹脂(図示せず)を充填した形態とすることができる。この場合、巻線2wの端部は、ケース4の外部に引き出して、封止樹脂から露出させる。封止樹脂は、例えば、エポキシ樹脂、ウレタン樹脂、シリコーン樹脂などが挙げられる。また、封止樹脂として、絶縁性及び熱伝導性に優れるフィラー、例えば、窒化珪素、アルミナ、窒化アルミニウム、窒化ほう素、ムライト、及び炭化珪素から選択される少なくとも1種のセラミックスからなるフィラーを含有すると、放熱性を更に高められる。
上記構成を具えるリアクトル1は、以下のようにして製造することができる。
上記構成を具えるリアクトル1は、通電条件が、例えば、最大電流(直流):100A~1000A程度、平均電圧:100V~1000V程度、使用周波数:5kHz~100kHz程度である用途、代表的には電気自動車やハイブリッド自動車などの車載用電力変換装置の構成部品に好適に利用することができる。
上記構成を具えるリアクトル1は、熱伝導率が2W/m・K超と熱伝導性に優れる放熱層42が底板部40とコイル2との間に介在されることで、使用時に生じたコイル2の熱及び磁性コア3の熱を放熱層42を介して、冷却ベースといった固定対象に効率よく放出できる。従って、リアクトル1は、放熱性に優れる。
上述した実施形態では、底板部と側壁部とが異なる材質で構成された形態を説明したが、両者が同材質で構成された形態とすることができる。例えば、両者をアルミニウムといった放熱性に優れる金属材料で構成すると、リアクトルの放熱性を更に高められる。特に、この形態では、封止樹脂を具える構成とすると、コイルや磁性コアの熱をケースに効率よく伝えられる上に、封止樹脂に絶縁性樹脂を利用することで、コイルの外周面と側壁部の内面との間の絶縁性を高められる。この形態でも、絶縁性材料からなる放熱層を具えることで、コイルのコイル設置面と底板部の内面との間隔を狭められることから、小型である。この形態では、コイルの外周面と側壁部の内面との間に絶縁を確保するための間隔を設ける。
上述した実施形態では、絶縁性接着剤により放熱層が構成された形態を説明したが、窒化アルミニウムやアルミナなどのセラミックスにより放熱層が構成された形態とすることができる。
上述した実施形態では、インシュレータ5の各周壁部51が一対の分割片511,512により構成される形態について説明した。その他、図7に示すインシュレータ5αのように、周壁部51αを一つの筒状体とすることができる。ここでは、インシュレータ5αを詳細に説明し、その他の構成は上述した実施形態と重複するため、説明を省略する。
或いは、磁性コア3の形成にあたり接着剤を用いない別の構成として、例えば、磁性コアを環状に保持可能な帯状締付材(図示せず)を利用することが挙げられる。帯状締付材は、例えば、磁性コアの外周に配置される帯部と、帯部の一端に装着されて帯部がつくるループを所定の長さに固定するロック部とを具えるものが挙げられる。ロック部は、突条を有する帯部の他端側領域が挿通される挿通孔と、この挿通孔に設けられて帯部の上記突条に噛み込む歯部とを有するものが挙げられる。そして、帯部の他端側領域の突条とロック部の歯部とがラチェット機構を構成することで、上記所定の長さのループを固定可能なものが好適に利用できる。
2:コイル 2a,2b:コイル素子 2d:コイル設置面
2r:コイル連結部 2w:巻線
3:磁性コア
31:内側コア部 31e:端面 31m:コア片
31g:ギャップ材 32:外側コア部 32e:内端面
32d:コア設置面
4:ケース 40:底板部 41:側壁部 42:放熱層
400,411:取付部 400h,411h:ボルト孔
410:端子台 410c:凹溝
5,5α:インシュレータ 51,51α:周壁部
511,512:分割片 513:平板部(設置面部)
514:掛止部 515:窓部 516:係合凹部
516α,526α:嵌合凹凸部
52,52α:枠状部 521:開口部 522:台座
523:突出部 525:突起部 526:係合凸部 527:枠部
6:パッキン 8:端子金具 81:溶接面 82:接続面
9:端子固定部材 91:ボルト 100:固定治具
101:本体 102:コア押付部
103:インシュレータ押付部 104:支持部
105,106:ボルト
Claims (6)
- 巻線を螺旋状に巻回してなるコイルとこのコイルが配置される磁性コアとを有する組合体と、この組合体を収納するケースとを具えるリアクトルであって、
前記組合体は、
前記コイルと前記磁性コアとの間を絶縁するインシュレータを具え、
前記ケースは、
前記リアクトルが固定対象に設置されるときに当該固定対象に固定される底板部と、
前記底板部に固定材により取り付けられ、前記組合体の周囲を囲む側壁部と、
前記底板部の内面に形成されて、当該底板部と前記コイルとの間に介在される放熱層とを具え、
前記底板部の熱伝導率は、前記側壁部の熱伝導率と同等以上であり、
前記放熱層は、熱伝導率が2W/m・K超の絶縁性材料により構成され、
前記インシュレータは、前記コイルの内周面と前記磁性コアとの間に介在される設置面部と、前記コイルを前記放熱層に均一的に接触させるために前記設置面部を前記コイルの内周面に押し付ける押付機構とを具えることを特徴とするリアクトル。 - 前記磁性コアは、
前記コイルが配置される内側コア部と、
前記コイルが配置されず、前記コイルから露出される外側コア部とを具え、
前記インシュレータは、
前記内側コア部の外周に配置されて、前記コイルと前記内側コア部との間に介在される周壁部と、
前記コイルの端面に当接されて、前記コイルと前記外側コア部との間に介在される枠状部とを具え、
前記周壁部及び前記枠状部は、互いに係合する係合部を有し、
前記周壁部は、前記設置面部を有し、
前記枠状部は、前記周壁部と組み合わせたときに前記設置面部を前記コイルの内周面に押し付ける突起部を有し、
前記押付機構は、前記係合部及び前記突起部により構成されることを特徴とする請求項1に記載のリアクトル。 - 前記放熱層は、絶縁性接着剤により構成された多層構造であり、
前記底板部は、導電性材料により構成されていることを特徴とする請求項1又は2に記載のリアクトル。 - 前記側壁部は、絶縁性材料により構成されていることを特徴とする請求項1~3のいずれか1項に記載のリアクトル。
- 前記放熱層は、アルミナのフィラーを含有するエポキシ系接着剤により構成された多層構造であり、
前記底板部は、アルミニウム又はアルミニウム合金により構成され、
前記側壁部は、絶縁性樹脂により構成されていることを特徴とする請求項1~4のいずれか1項に記載のリアクトル。 - 巻線を螺旋状に巻回してなるコイルと磁性コアとを組み付けて前記コイルと前記磁性コアとの組合体を作製し、底面部とこの底面部に立設されて前記組合体の周囲を囲む側壁部とを具えるケースに前記組合体を収納してリアクトルを製造するリアクトルの製造方法であって、
前記底板部の内面に、熱伝導率が2W/m・K超の絶縁性材料からなる放熱層を形成する工程と、
前記コイルと前記磁性コアとの間に両者を絶縁するインシュレータを配置し、このインシュレータにより前記コイルを前記放熱層に押し付けて、前記コイルを前記放熱層に均一的に接触させる工程と、
前記底板部に固定材により前記側壁部を取り付けて、前記ケースを形成する工程とを具えることを特徴とするリアクトルの製造方法。
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CN104733171A (zh) * | 2015-04-02 | 2015-06-24 | 上海楚尧电子科技有限公司 | 电抗器的一体式灌封结构及一体式灌封方法 |
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JP2019102734A (ja) * | 2017-12-06 | 2019-06-24 | トヨタ自動車株式会社 | リアクトルとその製造方法 |
JP7191535B2 (ja) * | 2018-03-29 | 2022-12-19 | 株式会社小松製作所 | リアクトルコア、リアクトル及びリアクトルコアの製造方法 |
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DE112011103832T5 (de) | 2013-08-22 |
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