WO2013168538A1 - Réacteur, convertisseur, dispositif de conversion d'énergie électrique et méthode de fabrication de pièce de noyau en résine - Google Patents

Réacteur, convertisseur, dispositif de conversion d'énergie électrique et méthode de fabrication de pièce de noyau en résine Download PDF

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Publication number
WO2013168538A1
WO2013168538A1 PCT/JP2013/061618 JP2013061618W WO2013168538A1 WO 2013168538 A1 WO2013168538 A1 WO 2013168538A1 JP 2013061618 W JP2013061618 W JP 2013061618W WO 2013168538 A1 WO2013168538 A1 WO 2013168538A1
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Prior art keywords
core
reactor
core piece
resin
coil
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PCT/JP2013/061618
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English (en)
Japanese (ja)
Inventor
茂樹 枡田
和宏 稲葉
Original Assignee
住友電気工業株式会社
住友電装株式会社
株式会社オートネットワーク技術研究所
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Publication of WO2013168538A1 publication Critical patent/WO2013168538A1/fr

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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
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • 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
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • 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
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles

Definitions

  • the present invention relates to a reactor having a coil and a magnetic core, a converter using the reactor, a power converter using the converter, and a method for manufacturing a resin core piece.
  • Reactor is one of the circuit components that perform voltage step-up and step-down operations.
  • the reactor is used for a converter mounted on a vehicle such as a hybrid vehicle or an electric vehicle.
  • a vehicle such as a hybrid vehicle or an electric vehicle.
  • the reactor for example, there is one shown in Patent Document 1.
  • Patent Document 1 discloses a reactor including a coil formed by winding a winding and a magnetic core inserted through the coil, and the magnetic core is configured by combining a plurality of divided core pieces.
  • Patent Document 1 discloses that the relative magnetic permeability of each divided core piece is made different in order to reduce the leakage magnetic flux.
  • the split core piece include a compacted body formed by pressure-molding soft magnetic powder, a molded and hardened body including soft magnetic powder and a resin, and a laminate including laminated magnetic steel sheets.
  • the molded cured body can set the mixing ratio of the soft magnetic powder and the resin in a wide range, it is considered that it is easy to change the relative permeability of the divided core pieces.
  • a reactor using a magnetic core having a part made of a molded hardened body has room for improvement in terms of productivity.
  • Molded cured bodies tend to be more fragile than compacted molded bodies because they contain a large amount of resin. Therefore, when producing a reactor using the magnetic core containing the resin core piece which consists of a shaping
  • peripheral edge is chamfered means that it is sufficient if a chamfered portion is formed as a result on the peripheral edge of one surface of the object (resin core piece). That is, not only the case where the chamfered portion is formed by scraping the periphery after forming the object, but also the case where the chamfered portion is already formed at the time of forming the object is included in the above expression. Therefore, “the peripheral edge is chamfered” is synonymous with the peripheral edge having a surface (chamfered portion) chamfered by some processing.
  • the reactor of the present invention is roughly classified into two forms.
  • a reactor according to the first aspect of the present invention is a reactor including a coil formed by winding a winding and a magnetic core formed by combining a plurality of divided core pieces.
  • At least one of the plurality of divided core pieces in the reactor of the present invention is a resin core piece (molded and cured body) containing soft magnetic powder and resin, and the content of the soft magnetic powder in the resin core piece is 75 volumes. %, And the peripheral edge of at least one surface of the resin core piece is chamfered over the entire circumference.
  • all of the split core pieces may be made of resin core pieces.
  • the reactor which concerns on a 1st form is called a core division type reactor.
  • the resin core piece which is one of a plurality of divided core pieces, may come into contact with other members in the process of manufacturing the reactor, and may be subjected to physical impact.
  • This resin core piece is fragile as compared with a divided core piece formed of a green compact or an electromagnetic steel sheet, and the peripheral edge of the surface of the resin core piece is particularly easily lost.
  • the peripheral edge of at least one surface of the resin core piece is chamfered over the entire circumference, that is, the corner portion between at least one surface of the resin core piece and the surface connected to it.
  • the reactor according to the second aspect of the present invention includes a coil formed by winding a winding and an integral magnetic core.
  • the magnetic core in the reactor of the present invention is a resin core piece (molded and hardened body) containing soft magnetic powder and a resin, and the content of the soft magnetic powder in the resin core piece is 75% by volume or less, and the resin core The peripheral edge of at least one surface of the piece is chamfered over the entire periphery.
  • the reactor which concerns on a 2nd form is called a core single-piece
  • the core single-unit reactor of the present invention is also less likely to have a chamfered peripheral edge for the same reason as the core-divided reactor of the present invention. As a result, when the reactor is manufactured, it is possible to greatly reduce the possibility that the resin core piece will be defective and become a defective product, and the yield (productivity) of the reactor can be improved.
  • one face of the resin core piece with the peripheral edge chamfered may be a face facing another member constituting the reactor.
  • At least one surface of the resin core piece is a member-facing surface that necessarily faces the other members constituting the reactor.
  • other members facing the resin core piece in the core split type reactor other split core pieces and coils can be mentioned, and when the reactor includes a bobbin, a bobbin can be mentioned.
  • a coil a bobbin when a bobbin is provided
  • the peripheral edge of the member facing surface of the resin core piece facing these “other members” is a surface that comes into contact with the other members in the process of manufacturing the reactor and is easily subjected to physical impact.
  • the periphery of the member facing surface of the relatively fragile resin core piece is chamfered, that is, the corners between the member facing surface and the surface connected to the resin core piece are not sharpened. It is possible to make it difficult to cause a defect at the peripheral edge.
  • one face of the resin core piece with the peripheral edge chamfered may be a face facing the other split core piece.
  • At least a part of the resin core piece may be arranged inside the coil.
  • the entire magnetic core is a resin core piece, at least a part of the resin core piece is always disposed inside the coil.
  • the content of the soft magnetic powder may be different between the part disposed inside the coil and the part exposed from the coil in the resin core piece integrated.
  • one surface of the resin core piece with the peripheral edge chamfered is formed on the inner peripheral surface of the coil.
  • the form which is an opposing surface can be mentioned.
  • the resin core piece having a portion disposed inside the coil is likely to be damaged during the insertion process inside the coil. This is because when the resin core piece is inserted into the inside of the coil, the inside of the coil is difficult to see from the outside of the coil, so that the resin core piece and the coil can easily come into contact with each other. Therefore, it is preferable to chamfer the peripheral edge of the coil facing surface facing the coil among the resin core pieces as in the above configuration, and thereby effectively preventing the loss of the coil facing surface in the resin core piece. Can do.
  • the chamfering may be an R chamfering of R0.5 mm to R5 mm.
  • R chamfering If the amount of R chamfering is too large (that is, if R is too large), the magnetic path area of the magnetic core may not be sufficient. On the other hand, if the amount of R chamfering is too small (that is, if R is too small), the effect of chamfering may not be sufficiently obtained. On the other hand, when R of the chamfering is 0.5 mm or more and 5 mm or less, the effect of chamfering can be sufficiently obtained while sufficiently securing the magnetic path area. A more preferable range of R is 2 mm or more and 3 mm or less.
  • a method for producing a resin core piece of the present invention is a method for producing a resin core piece for producing a resin core piece constituting at least a part of a magnetic core provided in a reactor, comprising a soft magnetic powder and a resin. And a preparatory step of preparing a composite material having a soft magnetic powder content of 75% by volume or less, and a molding step of filling the molding die with the composite material and molding a resin core piece.
  • the manufacturing method of the resin core piece of this invention is a metal mold
  • a resin core piece in which the periphery of the member facing surface is already chamfered during molding.
  • the resin core piece contains resin, if the corner portion connecting the surfaces of the resin core piece is sharp, when the resin core piece is removed from the molding die, molding corresponding to the corner portion is performed. In some cases, a part of the corner is attached to the corner of the mold, and the corner is damaged.
  • a chamfered shape can be formed on the periphery of at least one surface (referred to as a target surface) of the resin core piece, that is, the target surface and a surface connected to the target surface. Therefore, the resin core piece can be produced without causing a defect on the periphery of the target surface.
  • the method for producing a finger core piece of the present invention it is possible to avoid chamfering by forming the finger core piece and then scraping the periphery of the target surface of the finger core piece.
  • the surface of the chamfered portion (hereinafter, chamfered portion) is likely to be rough.
  • the molded hardened body has a configuration in which particles of soft magnetic powder are dispersed in the resin, and therefore, when a part of the molded hardened body is scraped off, particles are easily dropped off on the surface of the chamfered portion.
  • the chamfered shape is formed at the periphery of the target surface when the resin core piece is molded, the problem that the surface of the chamfered portion becomes rough does not occur.
  • the reactor of the present invention can be suitably used as a component part of a converter. That is, the converter of the present invention includes the reactor of the present invention.
  • the converter of the present invention includes a switching element, a drive circuit that controls the operation of the switching element, and the reactor of the present invention that smoothes the switching operation, and converts the input voltage by the operation of the switching element. A configuration is mentioned.
  • the converter of the present invention using the reactor of the present invention that is excellent in productivity contributes to the improvement of the productivity of a device (for example, a vehicle such as a hybrid car) provided with the converter of the present invention.
  • a device for example, a vehicle such as a hybrid car
  • the converter of the present invention can be suitably used as a component part of a power conversion device. That is, the power converter of the present invention includes the converter of the present invention.
  • the power converter of the present invention includes a converter of the present invention that converts an input voltage, and an inverter that is connected to the converter and converts between direct current and alternating current, and the electric power converted by the inverter
  • the structure which drives load is mentioned.
  • the power conversion device of the present invention using the reactor of the present invention that is excellent in productivity contributes to the improvement of the productivity of equipment (for example, a vehicle such as a hybrid car) provided with the power conversion device of the present invention.
  • equipment for example, a vehicle such as a hybrid car
  • the reactor of the present invention is excellent in productivity even though at least a part of the magnetic core provided in the reactor is made of a molded hardened body.
  • FIG. 1 is a schematic perspective view of a reactor provided with two coil elements which concern on Embodiment 1,2.
  • 1 is an exploded perspective view of a reactor according to a first embodiment. It is a disassembled perspective view of the reactor which concerns on Embodiment 2.
  • FIG. (A) is a schematic perspective view of a reactor provided with one coil element concerning Embodiment 4,
  • (B) is an exploded sectional view of the magnetic core of (A).
  • 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit which shows an example of the power converter device of this invention provided with the converter of this invention.
  • a reactor 1 according to the first embodiment will be described with reference to FIGS.
  • a reactor 1 according to the first embodiment includes a coil 2 including a pair of coil elements 2A and 2B, a magnetic core 3 formed by combining a plurality of divided core pieces, and a bobbin 4 that ensures insulation between the two and 3
  • the most distinctive feature of the core split type reactor 1 is that at least a part of the split core pieces constituting the magnetic core 3 is made of a molded hardened body containing soft magnetic powder and resin, and the molded hardened body The peripheral edge of at least one surface is chamfered over the entire periphery.
  • each structure of the reactor 1 of this Embodiment 1 is demonstrated in detail sequentially.
  • the coil 2 includes a pair of coil elements 2 ⁇ / b> A and 2 ⁇ / b> B and a coil element connecting portion 2 r that connects both the coil elements 2 ⁇ / b> A and 2 ⁇ / b> B.
  • the coil elements 2A and 2B are formed in a hollow cylindrical shape with the same number of turns and the same winding direction, and are arranged side by side so that the axial directions are parallel to each other.
  • the coil element connecting portion 2r is a U-shaped bent portion that connects the coil elements 2A and 2B on the other end side of the coil 2 (the right side in FIG. 4).
  • the coil 2 may be formed by spirally winding a single winding without a joint. Alternatively, the coil elements 2A and 2B may be formed by separate windings, and the coil elements 2A and 2B may be formed. You may form by joining the edge parts of a coil
  • a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor such as a flat wire or a round wire made of a conductive material such as copper, aluminum, or an alloy thereof can be suitably used.
  • the conductor is made of a copper rectangular wire
  • the insulation coating is made of a coated rectangular wire made of enamel (typically polyamideimide). It is a wound edgewise coil.
  • end face shape of each coil element 2A, 2B is made into the shape which rounded the rectangular corner
  • Both end portions 2a and 2b of the coil 2 are extended from the turn forming portion and connected to a terminal member (not shown).
  • An external device such as a power source for supplying power is connected to the coil 2 through this terminal member.
  • the magnetic core 3 As shown in FIG. 2, the magnetic core 3 according to the present embodiment includes divided core pieces 31 and 31 disposed inside the coil elements 2A and 2B, and divided core pieces 32 and 32 exposed from the coil elements 2A and 2B. And are combined in a ring shape.
  • the split core piece 31 is referred to as an inner core portion because it is disposed inside the coil elements 2A and 2B (that is, inside the coil 2).
  • the split core piece 32 is called an outer core portion because it is exposed from the coil elements 2A and 2B (coil 2).
  • a gap material made of a material having a lower relative permeability than the divided core pieces 31 and 32 may be interposed between the divided core pieces 31 and 32.
  • a nonmagnetic material can be used for the gap material.
  • the nonmagnetic material include unsaturated polyester, phenol resin, epoxy resin, polyester, polyphenylene sulfide (PPS) resin, and the like.
  • PPS polyphenylene sulfide
  • a magnetic material having a relative permeability exceeding 1 can be used for the gap material.
  • a magnetic material that is a mixture including the nonmagnetic material and magnetic material powder exemplified above can be used as the gap material.
  • the magnetic material powder include Fe powder, Fe—Si alloy powder, Sendust (Fe—Si—Al alloy) powder, and ferrite powder.
  • the relative permeability of the gap material can be adjusted by changing the content of the magnetic powder in the mixed material and the material of the magnetic powder.
  • the relative permeability of the constituent material of the gap material is smaller, the thickness of the gap material can be reduced and the magnetic core portion can be reduced in size. Further, the larger the relative permeability of the gap material, the smaller the leakage of magnetic flux in the vicinity of the gap material.
  • the relative magnetic permeability of the constituent material of the gap material is preferably more than 1 and less than 10, more preferably more than 1 and less than 2, further preferably 1.05 or more and less than 1.5, and particularly preferably 1.1. It is 1.4 or less. Of course, the relative permeability of the gap material is made lower than that of the split core piece.
  • the inner core portion 31 in the present embodiment is a resin core piece made of a substantially cuboid shaped cured body (the definition of the molded cured body will be described later).
  • the peripheral edges of the core facing surfaces 310 and 310 facing the outer core portions 32 and 32 are chamfered over the entire circumference (see the dotted circle in FIG. 2).
  • the core facing surface 310 is a member facing surface that faces the outer core portions 32 and 32 that sandwich the inner core portion 31 from the left and right.
  • the peripheral edge of the core facing surface 310 may be lost in contact with the bobbin 4).
  • the possibility of the defect at the time of assembling the reactor 1 can be greatly reduced.
  • the incidence of defective products of the reactor 1 can be reduced, and the productivity of the reactor 1 can be improved.
  • the chamfering of the core facing surface 310 may be C chamfering or R chamfering, but in this embodiment, the chamfering is R chamfering that is less likely to cause defects.
  • R chamfering is preferably R0.5 mm or more and R5.0 mm or less, more preferably C2.0 mm or more and C3.0 mm or less. If the R chamfering is in the above range, the peripheral edge of the core facing surface 310 can be effectively prevented from being lost, and the area of the core facing surface 310, that is, the magnetic path area can be sufficiently secured.
  • the peripheral edge of the coil facing surface 319 of the inner core portion 31 is also chamfered over the entire circumference (the dotted line circle in FIG. 2). See box).
  • the coil facing surfaces 319 are four surfaces of the inner core portion 31 other than the core facing surfaces 310 and 310, and when the inner core portion 31 is inserted into the coil elements 2A and 2B (coil 2), the coil elements 2A and 2B. It is a member opposing surface which opposes the inner peripheral surface of this.
  • the peripheral edge of the coil facing surface 319 may be lost due to contact with the inner peripheral surface of the coil elements 2 ⁇ / b> A and 2 ⁇ / b> B. There is also a possibility of damaging the insulation coating on the inner peripheral side of the elements 2A and 2B.
  • the defect or damage is highly likely to occur at the time of assembly, and the generated defect / damage cannot be easily confirmed from the outside. .
  • the possibility of the above-mentioned defect / damage can be greatly reduced, and the occurrence rate of defective products can be reduced.
  • the chamfering of the coil facing surface 319 may be C chamfering or R chamfering, but in this embodiment, it is C chamfering.
  • C chamfering is preferably C0.5 mm or more and C5.0 mm or less, more preferably C2.0 mm or more and C3.0 mm or less. If the chamfering is in the above range, the peripheral edge of the core facing surface 310 can be effectively prevented from being lost, and the area of the core facing surface 310, that is, the magnetic path area can be sufficiently secured.
  • the outer core parts 32 and 32 in this embodiment are the compacting body which comprises the magnetic core 3 by connecting with the said inner core parts 31 and 31 cyclically (the definition of a compacting body is mentioned later).
  • the shape of the outer core portions 32 and 32 is not particularly limited as long as the inner core portions 31 and 31 arranged in parallel can be connected.
  • the outer core portions 32 and 32 have their upper surfaces. Is a substantially domed columnar core piece.
  • the height of the outer core part 32 is higher than the height of the inner core part 31.
  • the lower end surface of the outer core portion 32 is flush with the lower end surface of the coil 2
  • the upper end surface of the outer core portion 32 is set to be not less than the upper end surface of the inner core portion 31 and not more than the upper end surfaces of the coil elements 2A and 2B of the coil 2.
  • the outer core part 32 can also be made into a molded hardened body like the inner core part 31. In that case, it is preferable to chamfer or chamfer the periphery of the core facing surface 320 facing the inner core portion 31 in the outer core portion 32. By doing so, the defect
  • the molded and hardened body constituting the inner core portion (divided core piece) 31 in the present embodiment is a magnetic body having a structure in which particles constituting soft magnetic powder are dispersed in a resin.
  • the soft magnetic powder contained in the molded hardened body iron, an iron-based alloy, a rare earth metal compound, or the like can be used.
  • a coating powder having an insulating coating on the surface of the soft magnetic particles can be used.
  • the eddy current loss in the molded and hardened body can be effectively reduced by using the coating powder.
  • the insulating coating include a phosphoric acid compound, a silicon compound, a zirconium compound, an aluminum compound, and a boron compound.
  • the average particle size of the soft magnetic powder is preferably 1 ⁇ m or more and 1000 ⁇ m or less, particularly preferably 10 ⁇ m or more and 500 ⁇ m or less.
  • the magnetic powder may be a mixture of a plurality of types of powders having different particle sizes.
  • thermosetting resin such as an epoxy resin, a phenol resin, a silicone resin, or a urethane resin
  • thermoplastic resins such as polyphenylene sulfide (PPS) resin, polyimide resin, and fluororesin, room temperature curable resin, or low temperature curable resin may be used.
  • PPS polyphenylene sulfide
  • BMC Bulk molding compound in which calcium carbonate or glass fiber is mixed with unsaturated polyester, millable silicone rubber, millable urethane rubber, or the like can also be used.
  • the molded hardened body may contain a ceramic filler.
  • the ceramic filler include at least one selected from silicon nitride, alumina, aluminum nitride, boron nitride, mullite, and silicon carbide. This ceramic filler contributes to the improvement in heat dissipation of the molded cured body and the suppression (uniform dispersion) of the uneven distribution of the soft magnetic powder in the molded cured body.
  • the content of the soft magnetic powder in the molded hardened body is preferably 20% by volume or more and 75% by volume or lower when the molded hardened body is 100%.
  • the soft magnetic powder is 20% by volume or more, it is easy to ensure magnetic characteristics such as relative magnetic permeability and saturation magnetic flux density.
  • the soft magnetic powder is 75% by volume or less, it is easy to mix with the resin, and the productivity of the molded cured body is excellent.
  • the molded hardened body can change the magnetic characteristics such as relative permeability by adjusting the content of the soft magnetic powder or changing the material of the soft magnetic powder.
  • the content of the soft magnetic powder is more preferably 40% by volume to 65% by volume.
  • the saturation magnetic flux density of the molded hardened body is easily set to 0.8 T or more because the content of the soft magnetic powder is 40 volume% or more.
  • the content of the soft magnetic powder is 65% by volume or less, the soft magnetic powder and the resin are more easily mixed, and the productivity is further improved.
  • the relative magnetic permeability of the molded cured product having the soft magnetic powder content in the above range is preferably 5 or more and 50 or less, more preferably 10 or more and 35 or less, and particularly preferably 20 or more and 30 or less.
  • the saturation magnetic flux density is preferably 0.6T or more, more preferably 0.8T or more, and particularly preferably 1.0T or more. Further, it is desirable that the heat conductivity of the molded cured body is 0.25 W / m ⁇ K or more.
  • the relative permeability and saturation magnetic flux density of the molded hardened body can be adjusted by changing the content of the magnetic powder. Usually, if the content of the magnetic powder is increased, the relative permeability and the saturation magnetic flux density are increased.
  • the relative permeability and saturation magnetic flux density of the molded hardened body can be adjusted by changing the material of the magnetic powder. Usually, if the relative magnetic permeability of the magnetic powder itself is increased, the relative permeability of the molded hardened body is increased, and if the saturation magnetic flux density of the magnetic powder itself is increased, the saturated magnetic flux density of the molded hardened body is increased.
  • the relative magnetic permeability of the molded and hardened body referred to here is obtained as follows.
  • a ring-shaped test piece having an outer diameter of 34 mm, an inner diameter of 20 mm, and a thickness of 5 mm is produced using the same material as the molded and cured body.
  • a BH curve tracer “BHS-40S10K” manufactured by Riken Denshi Co., Ltd. can be used.
  • the magnetization curve here is a so-called DC magnetization curve.
  • the saturation magnetic flux density of the molded hardened body is defined as the magnetic flux density when a magnetic field of 10,000 (Oe) is applied to the test piece of the molded hardened body with an electromagnet and sufficiently magnetically saturated.
  • molding hardening body when making a shaping
  • the molded cured body described above can be produced by a method for producing a resin core piece including the following preparation process and molding process.
  • a soft magnetic powder and a resin are prepared, and both are mixed to produce a composite material.
  • the ceramic filler may be mixed with the composite material. Note that the blending ratio of the soft magnetic powder and the resin in the composite material (in the case of including the ceramic filler, the blending ratio including the ceramic filler) may be considered to be the same as the blending ratio in the molded cured body.
  • a molding die is prepared, the composite material produced in the preparation step is filled into the molding die, the resin is cured, and a molded and cured body is completed.
  • methods for producing a molded cured body using a molding die include injection molding, transfer molding, MIM (Metal Injection Molding), cast molding, press molding using soft magnetic powder and powdered solid resin, and the like. Can be used.
  • injection molding a molding hardened body can be obtained by filling a molding die with a mixture of soft magnetic powder and resin in a predetermined pressure and molding, and then curing the resin.
  • transfer molding or MIM molding is performed by filling the above-mentioned mixed material into a molding die.
  • the molded material can be obtained by injecting the mixed material into a molding die without applying pressure and molding and curing the mixture.
  • the periphery of the core facing surface 310 of the split core piece 31 and the periphery of the coil facing surface 319 are chamfered.
  • the chamfering of the peripheral edge is preferably performed simultaneously with the formation of the split core piece 31. That is, it is preferable that a chamfered shape is formed on the periphery of the member facing surfaces 310 and 319 in the molded cured body by transferring the inner peripheral surface shape of the molding die.
  • the inner peripheral surface shape of the molding die is formed so that the corners connecting the surfaces to the member facing surfaces 310 and 319 of the molded cured body are not sharpened, the corresponding corners are formed. It is possible to avoid the ink from being attached to the corner of the metal mold.
  • the green compact forming the outer core portion (divided core piece) 32 is typically manufactured by press-molding soft magnetic powder having an insulating film on the surface and then appropriately performing heat treatment. can do.
  • resin such as thermoplastic resin or higher fatty acid is added to coating powder or ferrite powder that has an insulating coating on the surface of particles made of soft magnetic materials such as iron-based materials and rare earth metal compounds.
  • a mixed material to which an agent (disappeared by the heat treatment or changed into an insulator) is added may be used.
  • the soft magnetic particles are covered with an insulating coating (for example, a phosphoric acid compound, a silicon compound, a zirconium compound, an aluminum compound, a boron compound, etc.), and a compacted body in which an insulator is interposed between the particles. Is obtained.
  • the green compact provided with an insulating coating is excellent in insulation and can reduce eddy current loss.
  • the soft magnetic material is ferrite, the insulation is excellent even if the insulation coating is not provided.
  • the average particle size of the soft magnetic powder used is preferably 1 ⁇ m or more and 1000 ⁇ m or less, and particularly preferably 10 ⁇ m or more and 500 ⁇ m or less.
  • the soft magnetic powder may be a mixture of a plurality of types of powders having different particle sizes. Note that the size of the soft magnetic powder in the green compact and the powder used for the material are substantially the same (maintained).
  • the content of the soft magnetic powder (magnetic component) in the green compact is preferably 75% by volume or more, more preferably 80% by volume or more when the green compact is 100%. desirable.
  • the adjustment of the content of the soft magnetic powder in the green compact is, for example, the thickness of the insulating coating formed on the surface of the magnetic particles, and the amount of resin or additive added to the soft magnetic powder during the production of the green compact Can be adjusted by.
  • the green compact has a higher relative permeability than the above-mentioned molded hardened body. In addition, it tends to be a high saturation magnetic flux density. It is desirable that the powder compact has a relative permeability of 50 to 500, a saturation magnetic flux density of 1.0 T or more, and a thermal conductivity of 10 W / m ⁇ K or more.
  • the magnetic properties of the green compact can be adjusted by changing the content of the soft magnetic powder.
  • the magnetic characteristics of the green compact can be adjusted by changing the material of the soft magnetic powder.
  • the magnetic characteristics (particularly, the saturation magnetic flux density) of the green compact can be changed by adjusting the molding pressure during pressure molding. In that case, a compacting body with a high saturation magnetic flux density can be obtained by increasing the molding pressure.
  • the reactor 1 of the present embodiment includes a bobbin 4 that ensures insulation between the coil 2 and the magnetic core 3.
  • the bobbin 4 in the present embodiment is composed of a pair of bobbin members 41 and 42. Since both the bobbin members 41 and 42 have almost the same configuration, only the bobbin member 42 will be described below, and the same configuration as the bobbin member 42 in the bobbin member 41 is denoted by the same reference numeral as the bobbin member 42. A description thereof will be omitted.
  • the bobbin member 42 includes a flat plate portion 420, cylindrical portions 421, 421, a pedestal portion 422, and a partition portion 423, and is integrally formed by, for example, injection molding.
  • the material of the bobbin member 42 include a thermosetting resin such as an epoxy resin, a silicone resin, and an unsaturated polyester, and a thermoplastic insulating resin such as a PPS resin and a liquid crystal polymer (LCP).
  • This insulating resin may contain at least one ceramic filler selected from silicon nitride, alumina, aluminum nitride, boron nitride, mullite, and silicon carbide.
  • the flat plate portion 420 is literally a flat plate member.
  • the flat plate portion 420 is interposed between the core facing surface 310 of the inner core portion 31 and the core facing surface 320 of the outer core portion 32, and the magnetic core 3 functions as a gap material for adjusting the magnetic characteristics of the whole.
  • the flat plate portion 420 is also interposed between the end surfaces of the coil elements 2A and 2B and the core facing surface 320 of the outer core portion 32, and provides insulation between the end surfaces of the coil elements 2A and 2B and the outer core portion 32. It also has a function to ensure it.
  • the cylindrical portions 421 and 421 are provided in parallel on one surface side of the flat plate portion 420.
  • the outer peripheral edge shape of the cylindrical portion 421 is substantially equal to the inner peripheral edge shape of the coil element 2 ⁇ / b> A (2 ⁇ / b> B), and the inner peripheral edge shape of the cylindrical portion 421 is substantially equal to the outer peripheral edge shape of the inner core portion 31. Therefore, when the reactor 1 is completed by combining all the members shown in FIG. 2, the cylindrical portions 421 and 421 are interposed between the inner core portions 31 and 31 and the coil elements 2A and 2B. It has a function of ensuring insulation between 2A (2B).
  • the pedestal portion 422 is a bowl-shaped portion that protrudes in the direction opposite to the protruding direction of the cylindrical portions 421 and 421 on the upper end surface of the flat plate portion 420. Therefore, when the reactor 1 is completed by combining all the members shown in FIG. 2, the pedestal portion 422 is interposed between the coil element connecting portion 2 r of the coil 2 and the outer core portion 32, and between the two 2 r and 32. It has a function to ensure insulation.
  • the partitioning part 423 is a protrusion disposed between the cylindrical parts 421 and 421 on the same side of the flat part 420 as the cylindrical parts 421 and 421.
  • the partition portion 423 is interposed in the gap between the coil elements 2A and 2B when the reactor 1 is completed by combining all the members shown in FIG. 2, and has a function of ensuring insulation between the two elements 2A and 2B.
  • the reactor 1 having the above-described configuration can be produced with high yield because the magnetic core 3 is less likely to be defective during the manufacturing process, and the incidence of defective products due to the defect is low.
  • the core facing surface 310 on which a physical impact is likely to occur is that the magnetic core 3 is less likely to be damaged. This is because the peripheral edge of the coil facing surface 319 is chamfered and the peripheral edge is difficult to be lost.
  • the magnetic core 3 of the reactor 1 shown in FIG. 3 is configured by combining two divided core pieces 35 and 35 having the same shape. Both split core pieces 35, 35 have the same shape.
  • the split core piece 35 is a substantially U-shaped molded cured body when viewed from above, and includes a base portion 35A and a pair of overhang portions 35B and 35B extending from the base portion 35A toward the coil 2. .
  • the base portion 35A is a portion corresponding to the outer core portion 32 (see FIG. 2) of the first embodiment.
  • the upper end surface of the base portion 35A is flush with the upper end surfaces of the overhang portions 35B and 35B, but the lower end surface of the base portion 35A is lower than the lower end surfaces of the overhang portions 35B and 35B. Therefore, when the split core pieces 35 and 35 are assembled to the coil 2, the lower end surface of the base portion 35 ⁇ / b> A of the split core piece 35 is flush with the lower end surface of the coil 2.
  • the overhang portions 35B and 35B are portions having approximately half the length of the coil elements 2A and 2B, respectively. Therefore, when the two divided core pieces 35 and 35 are inserted into the coil elements 2A and 2B from both ends of the coil elements 2A and 2B, respectively, the overhanging portion 35B of one divided core piece 35 and the other divided piece are separated. A portion corresponding to the inner core portion 31 (see FIG. 2) of the first embodiment is formed by the overhang portion 35B of the core piece 35.
  • the periphery of the member facing surface of the split core piece 35 having the above configuration is also chamfered in the same manner as in the first embodiment. Specifically, the periphery of the core facing surface 350 of the overhang portion 35B is chamfered, and the periphery of the coil facing surface 359 of the protruding portion 35B is chamfered (see the dotted circle in FIG. 3). By doing so, it can suppress that a defect
  • projection part 35B in 35 A of base parts of the split core piece 35 is formed is also a member opposing surface which opposes the coil 2, the chamfering of the periphery of the surface is not performed in this embodiment.
  • the peripheral edge of this surface may be chamfered.
  • the bobbin 4 according to the second embodiment includes a pair of bobbin members 45 and 46. Since both the bobbin members 45 and 46 have almost the same configuration, the description of the bobbin member 46 will be mainly given below. The same configuration as the bobbin member 45 in the bobbin member 45 is the same as the bobbin member 46. The description is omitted.
  • the bobbin member 46 includes a frame-shaped portion 460, cylindrical portions 461, 461, a pedestal portion 462, and a partition portion 463.
  • the bobbin member 46 can be manufactured using the same material and the same molding method as the bobbin member 42 (see FIG. 2) of the first embodiment.
  • the frame-like portion 460 is a member having a hole having the same size as the inner diameter of the tubular portion 461 at a formation position of the tubular portion 461 described later.
  • the overhanging portion 35 ⁇ / b> B of the split core piece 35 is inserted into the cylindrical portion 461 from the hole of the frame-like portion 460.
  • the frame-like portion 460 is interposed between the end surfaces of the coil elements 2A and 2B and the base portion 35A of the split core piece 35 to ensure insulation between the end surfaces of the coil elements 2A and 2B and the base portion 35A. Has a function to secure.
  • a pair of cylindrical portions 461 and 461 are provided in parallel on one surface side of the frame-like portion 460.
  • the outer peripheral shape of the cylindrical portion 461 is substantially equal to the inner peripheral shape of the coil element 2A (2B), and the inner peripheral shape of the cylindrical portion 461 is substantially equal to the outer peripheral shape of the overhanging portion 35B of the split core piece 35. . Therefore, when the reactor 1 is completed by combining all the members shown in FIG. 3, the tubular portion 461 is interposed between the overhang portion 35B and the coil element 2A (2B), and both 35B, 2A (2B) ) Has a function to ensure insulation.
  • the axial length of the cylindrical portion 461 of the bobbin member 46 on the right side of the paper surface is longer than the axial length of the cylindrical portion 461 of the bobbin member 45 on the left side of the paper surface. Is approximately equal to the axial length of the coil elements 2A and 2B.
  • the gap defining portion 46g that protrudes inward in the radial direction of the tubular portion 461 is formed on two surfaces facing the height direction of the bobbin member 46. Is formed.
  • the overhanging portion 35B of the split core piece 35 on the right side of the paper surface inserted into the cylindrical portion 461 of the bobbin member 46 on the right side of the paper surface is inward of the gap defining portion 46g in the bobbin member 46. It is stopped by the surface.
  • the overhanging portion 35B of the split core piece 35 on the left side of the paper surface inserted into the cylindrical portion 461 of the bobbin member 45 on the left side of the paper surface passes through the cylindrical portion 461 of the bobbin member 45 and the gap defining portion 46g in the bobbin member 46. It is stopped against the outer surface of the.
  • the air gap is formed between the projecting portions 35B and 35B without directly contacting the projecting portion 35B of the left split core piece 35 and the projecting portion 35B of the right split core piece 35. Is done.
  • the pedestal portion 462 and the partition portion 463 have the same functions and the same functions as the pedestal portion 422 and the partition portion 423 provided in the bobbin member 42 of the first embodiment.
  • the reactor 1 according to the second embodiment can also be produced with high yield because the magnetic core 3 is not easily damaged during the manufacturing process.
  • the reason why the magnetic core 3 is less likely to be damaged is that the peripheral edges of the core facing surface 350 and the coil facing surface 359, which are susceptible to physical impact, are chamfered among the divided core pieces 35 and 35, and the peripheral edge is less likely to be lost. Because.
  • Embodiment 3 About the division
  • the split core piece (outer core part) 32 is also a resin core piece.
  • the divided core piece (outer core portion) 32 is a resin core piece
  • the divided core piece (inner core portion) 31 is a green compact. In that case, it is good also as what connected the inner core part 31 by arranging a some compacting body and a some gap board alternately.
  • one divided core piece 35 is a green compact and the other divided core piece 35 is a molded hardened body.
  • each divided core piece When viewed from the top, the two divided core pieces are approximately L-shaped. In that case, each divided core piece includes a portion corresponding to the outer core portion and a portion corresponding to the inner core portion inserted into one coil element. At least one of the two divided core pieces is a molded cured body.
  • Embodiment 4 demonstrates the example which applied the structure of this invention to the core division
  • the coil 2 'provided in the reactor 1' shown in FIG. 4 (A) includes only one coil element 2C, and the end portions 2a and 2b are drawn out from this one coil element 2C.
  • the magnetic core 3 'of the reactor 1' includes a split core piece (inner core portion) 31 'disposed inside the coil element 2C and a split core piece (outer core portion) 32' exposed from the coil element 2C. .
  • the inner core portion 31 ' has a cylindrical shape corresponding to the internal shape of the coil element 2C.
  • the outer core portion 32 ' is further divided into a cylindrical divided core piece 32A and a pair of plate-like divided core pieces 32B and 32C disposed at both ends of the cylindrical divided core piece 32A.
  • the magnetic properties of the divided core pieces 31 ', 32A, 32B, 32C are preferably changed depending on how the magnetic properties of the entire reactor 1' are set.
  • the split core piece 31 ' is a molded and hardened body, and the rest is a compacted body, and all the split core pieces are formed and hardened bodies.
  • the structure is limited to this configuration. I don't mean.
  • the chamfering position of the split core piece (inner core portion) 31 ′ is the periphery of the upper surface and the lower surface facing the plate-like split core pieces 32 ⁇ / b> B and 32 ⁇ / b> C constituting the outer core portion 32 ′.
  • This periphery is the periphery of the core facing surface that faces the plate-like divided core pieces 32B and 32C and the periphery of the coil facing surface that faces the inner peripheral surface of the coil element 2C.
  • the chamfering position of the cylindrical divided core piece 32A is the inner peripheral edge and the outer peripheral edge of the end surface facing the plate-shaped divided core piece 32B (32C).
  • the inner peripheral edge is the peripheral edge of the core facing surface facing the plate-like divided core pieces 32B and 32C, and the peripheral edge of the coil facing surface facing the outer peripheral surface of the coil element 2C.
  • the chamfering position of the plate-shaped divided core piece 32B (32C) is the periphery of the lower surface (upper surface) facing the upper end surface (lower surface) of the cylindrical divided core piece 32A.
  • a single core reactor in which the magnetic core is an integral reactor that is, a core single core type reactor in which the magnetic core has no split structure will be briefly described.
  • the magnetic core provided in the core-type reactor consists of an annular resin core piece with no joints.
  • a coil is completed by winding a winding around the magnetic core.
  • the ring shape of the resin core piece may be a racetrack shape like the magnetic core 3 of the first and second embodiments, an elliptical shape including a circle, or a polygonal shape including a rectangle. good. Further, the ring of the resin core piece may be closed or open. When the ring is open (for example, in the case of a substantially C-shaped resin core piece), the open part functions as an air gap. Of course, a gap material made of alumina or the like may be sandwiched between the open portions.
  • resin core piece having a rectangular cross section and an annular shape as a whole
  • the peripheral edges of two opposed end surfaces in the open portion also extend over the entire circumference. It is preferable to chamfer.
  • the resin core piece made of the molded and hardened body is less likely to be damaged when the reactor is manufactured, particularly when the winding is wound around the magnetic core, and the occurrence rate of defective products due to the defect can be reduced. it can.
  • the reactors of the first to fifth embodiments are used in 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
  • the present invention can be used for a component part of a converter mounted on a vehicle such as an automobile or a hybrid car, or a component part of a power conversion device including this converter.
  • an inductance satisfying 10 ⁇ H or more and 2 mH or less of the inductance when the DC current is 0 A and 10% or more of the inductance when the current is maximum is 0 A can be suitably used.
  • a vehicle 1200 such as a hybrid vehicle or an electric vehicle is used for traveling by being driven by a main battery 1210, a power converter 1100 connected to the main battery 1210, and power supplied from the main battery 1210 as shown in FIG.
  • the motor (load) 1220 is provided.
  • the motor 1220 is typically a three-phase AC motor, which drives the wheel 1250 when traveling and functions as a generator during regeneration.
  • vehicle 1200 includes an engine in addition to motor 1220.
  • an inlet is shown as a charge location of the vehicle 1200, it is good also as a form provided with a plug.
  • the power conversion device 1100 includes a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 and performing mutual conversion between direct current and alternating current.
  • the converter 1110 shown in this example boosts the DC voltage (input voltage) of the main battery 1210 of about 200V to 300V to about 400V to 700V when the vehicle 1200 is running, and supplies the inverter 1120 with power.
  • converter 1110 steps down DC voltage (input voltage) output from motor 1220 via inverter 1120 to DC voltage suitable for main battery 1210 during regeneration, and causes main battery 1210 to be charged.
  • the inverter 1120 converts the direct current boosted by the converter 1110 into a predetermined alternating current when the vehicle 1200 is running, and supplies the motor 1220 with electric power. During regeneration, the alternating current output from the motor 1220 is converted into direct current and output to the converter 1110. is doing.
  • the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor L, and converts input voltage by ON / OFF repetition (switching operation). (In this case, step-up / down pressure) is performed.
  • a power device such as FET or IGBT is used.
  • the reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that prevents the change of the current to flow through the circuit.
  • the reactor L the reactor described in the above embodiment is used.
  • the vehicle 1200 is connected to the converter 1110, the power supply converter 1150 connected to the main battery 1210, and the sub-battery 1230 and the main battery 1210 that are power sources of the auxiliary devices 1240.
  • Auxiliary power supply converter 1160 for converting the high voltage 1210 to a low voltage is provided.
  • the converter 1110 typically performs DC-DC conversion, while the power supply device converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Some power supply device converters 1150 perform DC-DC conversion.
  • the reactors of the power supply device converter 1150 and the auxiliary power supply converter 1160 have the same configuration as the reactors of the above-described embodiments and modified embodiments, and a reactor whose size and shape are appropriately changed can be used.
  • the reactor of the above-described embodiment can be used for a converter that performs conversion of input power and that only performs step-up or converter that performs only step-down.
  • the reactor of the present invention can be used as a component part of a power conversion device such as a bidirectional DC-DC converter mounted on a vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle.
  • a power conversion device such as a bidirectional DC-DC converter mounted on a vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle.

Abstract

L'invention concerne un réacteur avec une productivité supérieure grâce à un noyau magnétique qui comprend des pièces de noyau en résine dans lesquelles les défauts ne se produisent pas facilement. Ce réacteur comprend une bobine (2) formée en enroulant un enroulement et un noyau magnétique (3) situé à l'intérieur de cette bobine (2). Le noyau magnétique (3) est constitué d'une combinaison d'une pluralité de pièces de noyau divisées (31, 31, 32, 32). Au moins une pièce de noyau divisée (31, 31) de la pluralité de pièces de noyau divisées (31, 31, 32, 32) comprend une poudre magnétique à aimantation temporaire et une résine et la pièce de noyau en résine est formée à partir d'un corps moulé et durci dans lequel la fraction volumique de poudre magnétique à aimantation temporaire est inférieure ou égale à 75 %. Le bord périphérique d'au moins une surface de cette pièce de noyau en résine (31, 31) est chanfreiné sur toute la périphérie. Une surface faisant face au noyau (310) de la pièce de noyau en résine (31) qui fait face à une autre pièce de noyau divisée (32) et une surface faisant face à la bobine (319) qui fait face à la bobine (2) peuvent être utilisées comme une surface du noyau magnétique (31) qui est chanfreinée.
PCT/JP2013/061618 2012-05-09 2013-04-19 Réacteur, convertisseur, dispositif de conversion d'énergie électrique et méthode de fabrication de pièce de noyau en résine WO2013168538A1 (fr)

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WO2017135319A1 (fr) * 2016-02-03 2017-08-10 株式会社オートネットワーク技術研究所 Réacteur
CN112053843A (zh) * 2020-08-17 2020-12-08 包头韵升强磁材料有限公司 一种大尺寸烧结钕铁硼坯料的成型模压方法

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JP7255153B2 (ja) * 2018-12-07 2023-04-11 株式会社プロテリアル リアクトルおよびその製造方法
JP2020043355A (ja) * 2019-11-21 2020-03-19 株式会社オートネットワーク技術研究所 リアクトル

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JP2009027007A (ja) * 2007-07-20 2009-02-05 Toyota Motor Corp リアクトルコアおよびリアクトル
JP2009224584A (ja) * 2008-03-17 2009-10-01 Toyota Motor Corp リアクトル装置
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