WO2014024555A1 - Réacteur, ensemble pour réacteur, convertisseur et dispositif de conversion d'énergie - Google Patents

Réacteur, ensemble pour réacteur, convertisseur et dispositif de conversion d'énergie Download PDF

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Publication number
WO2014024555A1
WO2014024555A1 PCT/JP2013/065559 JP2013065559W WO2014024555A1 WO 2014024555 A1 WO2014024555 A1 WO 2014024555A1 JP 2013065559 W JP2013065559 W JP 2013065559W WO 2014024555 A1 WO2014024555 A1 WO 2014024555A1
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WIPO (PCT)
Prior art keywords
coil
case
reactor
assembly
core
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PCT/JP2013/065559
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English (en)
Japanese (ja)
Inventor
康 野村
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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Application filed by 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 filed Critical 住友電気工業株式会社
Publication of WO2014024555A1 publication Critical patent/WO2014024555A1/fr

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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
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306—Fastening or mounting coils or windings on core, casing or other support
    • 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
    • H01F27/33—Arrangements for noise damping

Definitions

  • the present invention relates to a reactor assembly, a reactor, a converter including a reactor, and a power including a converter, which are used for components of a power conversion device such as an in-vehicle DC-DC converter mounted on a vehicle such as a hybrid vehicle.
  • the present invention relates to a conversion device.
  • the present invention relates to a reactor that can reduce noise and has excellent assembly workability.
  • Patent Document 1 describes a coil used as a reactor used in a converter mounted on a vehicle such as a hybrid vehicle, and a coil in which a pair of cylindrical coil elements formed by winding a winding are arranged side by side, and each coil element is disposed.
  • the reactor further includes an insulator made of an inner bobbin and an outer bobbin made of resin.
  • a cylindrical inner bobbin is interposed between the coil element and the inner partial core, and an outer bobbin having a rectangular frame shape is provided on the end face of the coil. It is arranged to enhance the insulation between the coil and the magnetic core.
  • Patent Document 1 proposes to reduce noise by using a sealing resin containing a filler having a specific gravity higher than that of the resin and increasing the specific gravity of the sealing material.
  • this reactor has a configuration in which the inner bottom surface of the case and the outer partial core are in contact with each other (FIG. 3 of Patent Document 1), and noise may occur depending on the form of the magnetic core.
  • a magnetic core using a powder compact formed from a soft magnetic metal powder such as iron (hereinafter referred to as a powder core), compared to using a laminated steel sheet, Vibration due to magnetostriction is likely to occur.
  • a dust core when used as the magnetic core, if the magnetic core is supported in contact with the case as described above, the vibration of the magnetic core is caused by the vibration of the magnetic core due to magnetostriction. It is considered that noise can be generated by propagation to a cooling base (for example, a cooling base).
  • a cooling base for example, a cooling base
  • vibration generated during operation or the like is transmitted to the magnetic core through the case, and noise may be generated due to propagation of the vibration. . Further, the magnetic core may be damaged by the vibration propagated through the case.
  • the reactor may be in the form of a coil in contact with a metal case.
  • the vibration generated when the coil is excited can be directly transmitted to the case.
  • the vibration during operation can be directly transmitted to the coil through the case.
  • one of the objects of the present invention is to provide a reactor that can reduce noise and is excellent in assembly workability, and a reactor assembly.
  • Another object of the present invention is to provide a converter including the reactor and a power conversion device including the converter.
  • the present invention achieves the above object by devising the shape of the insulator so that the combination of the coil and the magnetic core can be maintained in a suspended state in a bottomed cylindrical case.
  • a reactor according to the present invention includes a cylindrical coil formed by winding a winding, a magnetic core having a portion where the coil is disposed, a storage portion disposed between the coil and the portion where the coil is disposed, and the coil.
  • An insulator having an exposed portion disposed in contact with the end surface of the coil, and a bottomed cylindrical case that houses an assembly of the coil, the magnetic core, and the insulator.
  • a gap is provided between the inner bottom surface of the case and both the coil and the magnetic core.
  • the exposed portion of the insulator includes a support portion that supports the combination of the coil and the magnetic core in a state where the gap is formed with respect to the case.
  • the reactor of the present invention is a state in which a part (support part) of the insulator is supported by the case, so that there is a gap between the combination of the coil and the magnetic core and the inner bottom surface of the case, that is, the combination. Is maintained in a suspended state in the case. Since the magnetic core is not in contact with the case, noise caused by magnetostriction can be reduced or prevented even when the magnetic core generates vibration due to magnetostriction. In addition, since the coil is not in contact with the case, the vibration of the coil cannot be directly transmitted to the case, so that noise caused by this vibration can be reduced or prevented.
  • the reactor of the present invention can reduce noise. Since this noise reduction / prevention effect can be obtained regardless of the presence or absence of the sealing resin and the material of the sealing resin, the reactor of the present invention has a high degree of freedom in selecting the sealing resin.
  • the reactor of this invention changes the shape of both the insulator and case which are the components of the conventional reactor, and there is substantially no increase in the components for noise reduction. Therefore, the reactor of the present invention has a small number of parts and is excellent in assembling workability.
  • the reactor according to the present invention is in a state in which the above-mentioned assembly is suspended in the case, even when the case is made of metal, the insulation between the coil or magnetic core and the case can be improved.
  • the exposed portion of the insulator includes a base plate protruding in the axial direction of the coil, and the support portion is a part of the base plate.
  • a combination of a coil and a magnetic core is provided by providing a receiving part for placing a part of the base plate in the case and storing the assembly in the case so as to be placed on the receiving part.
  • a receiving part for placing a part of the base plate in the case and storing the assembly in the case so as to be placed on the receiving part.
  • At least one of a protrusion and a through hole is provided in the support portion, and at least one of an engagement groove into which the protrusion is fitted and an engagement protrusion through which the through hole is inserted is provided in the case.
  • the combination of the coil and the magnetic core can be accurately positioned on the case by fitting the protrusion and the engagement groove and the through hole and the engagement protrusion, and the suspension is suspended.
  • the state can be easily formed.
  • the said form can maintain the suspended state over a long period of time, and is hard to slip
  • the assembly can be easily and accurately stored in the case using the protrusion, the engagement protrusion, or the like as a guide. Therefore, the said form can reduce a noise and is excellent in assembly workability
  • an embodiment including a sealing resin filled in the gap may be mentioned.
  • the sealing resin filled in the gap can easily reduce the propagation of vibration from the coil or magnetic core to the case and the vibration from the case to the coil or magnetic core, so that noise can be further reduced. .
  • an effect of improving insulation between the coil or magnetic core and the case and improving heat dissipation can be expected.
  • a form including a sealing resin filled from the inner bottom surface of the case to the contact portion between the support part and the case can be mentioned.
  • the case is integrally formed with a converter case.
  • the converter reactor is housed in the converter case.
  • the case for storing the combined assembly of the coil and the magnetic core is not independent of the converter case and is integrated, so that a process of fixing the independent case to the converter case is unnecessary, and assembly workability is improved. Excellent.
  • the reactor assembly according to the present invention includes a cylindrical coil formed by winding a winding, a magnetic core having a portion where the coil is disposed, and a storage disposed between the coil and the portion where the coil is disposed. And an insulator having a portion and an exposed portion disposed in contact with the end face of the coil. And when the said assembly is accommodated in a bottomed cylindrical case, the exposed part of the said insulator will be in the state which formed the clearance gap between both the inner bottom face of the said case, the said coil, and the said magnetic core. And a support portion for supporting the coil and the magnetic core with respect to the case.
  • the assembly for the reactor of the present invention is housed in a case, and a part of the insulator (support part) is supported by the case so that the combination of the coil and the magnetic core and the case are similar to the reactor of the present invention.
  • a gap is provided between the inner bottom surface. That is, the above-mentioned combination can be maintained in a state suspended in the case.
  • the reactor assembly of the present invention also reduces or prevents noise caused by magnetostriction, noise caused by coil vibration, and noise caused by propagation of vibration from the case, as in the case of the reactor of the present invention. it can.
  • the reactor assembly according to the present invention has substantially no increase in the number of parts for noise reduction, and therefore has a small number of parts and is excellent in assembling workability.
  • the reactor according to the present invention and the assembly for the reactor according to the present invention can be suitably used for the components of the converter.
  • the converter of the present invention includes the reactor of the present invention.
  • the converter of the present invention can reduce noise by including the reactor of the present invention that can reduce noise.
  • the converter of this invention is excellent in productivity by providing the reactor of this invention which is excellent in assembly workability
  • the converter of the present invention can be suitably used as a component part of a power conversion device.
  • the power converter of the present invention includes the converter of the present invention.
  • the power conversion device of the present invention can reduce noise by including the converter of the present invention that can reduce noise.
  • the power conversion device of the present invention is excellent in productivity by including the converter of the present invention which is excellent in assembling workability.
  • the reactor according to the present invention, the assembly for the reactor according to the present invention, the converter according to the present invention, and the power converter according to the present invention can reduce noise and have excellent assembly workability.
  • FIG. 1 is a schematic perspective view showing a reactor of Embodiment 1.
  • FIG. 1 is an exploded perspective view showing an outline of a reactor of Embodiment 1.
  • FIG. 2 is a partial cross-sectional view showing a (A)-(A) cross section of the reactor shown in FIG.
  • FIG. 2 is an exploded perspective view showing an outline of a reactor assembly provided in the reactor of the first embodiment.
  • FIG. 3 is an explanatory diagram for explaining an engagement state between an insulator provided in the reactor of Embodiment 1 and a case.
  • FIG. 5 is an explanatory view for explaining an engagement state between another form of the insulator provided in the reactor of the first embodiment and a case.
  • FIG. 3 is an exploded perspective view showing an outline of a reactor according to a second embodiment.
  • 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit diagram which shows an example of the power converter device of this invention provided with the converter of this invention.
  • the reactor 1A includes a coil 2 formed by winding a winding 2w, an annular magnetic core 3 (FIG. 4) in which the coil 2 is partially arranged, and an insulator 5A that enhances insulation between the coil 2 and the magnetic core 3. And a bottomed cylindrical case 4A for housing the assembly 10A of the coil 2, the magnetic core 3, and the insulator 5A.
  • Reactor 1A is an inner bottom surface 40i (FIG. 3) of case 4A by engagement of a part of the exposed portion (here part of base plate 54) arranged in the insulator 5A and outside of coil 2 with case 4A. The greatest feature is that the combination is supported in a state where a gap g (FIG.
  • the coil 2 includes a pair of coil elements 2a and 2b formed by spirally winding a winding 2w, and a U-shaped connecting portion 2r that connects both the coil elements 2a and 2b.
  • the coil elements 2a and 2b are hollow cylindrical bodies having the same number of turns, and are arranged in parallel (side by side) so that the axial directions are parallel to each other.
  • each of the coil elements 2a and 2b is an edgewise coil in which a covered rectangular wire is edgewise wound.
  • the end faces of the coil elements 2a and 2b are each formed of a frame-like surface corresponding to the width of the flat wire as shown in FIG.
  • the magnetic core 3 includes a pair of columnar inner core portions 31 (FIG. 4) and a pair of columnar outer core portions 32 (FIGS. 2 and 4). Each inner core portion 31 is inserted and arranged in the coil elements 2a and 2b arranged side by side, and is used as a coil arrangement portion.
  • the outer core portion 32 is a portion that is exposed from the coil 2 and is not substantially disposed.
  • the outer core portions 32 are arranged so as to connect the inner core portions 31 arranged side by side to form an annular magnetic core 3.
  • the insulator 5A is disposed between the coil elements 2a and 2b and the inner core portion 31 (coil placement portion), and includes a cylindrical portion 51A that covers the outer peripheral surface of the inner core portion 31, and both It comprises a pair of frame plate portions 52A arranged in contact with the end faces of the coil elements 2a, 2b, and is made of an insulating resin.
  • the cylindrical portion 51A is a storage portion covered with the coil 2, and the frame plate portion 52A is an exposed portion disposed outside the coil 2.
  • the cylindrical portion 51A enhances the insulation between the coil elements 2a, 2b and the inner core portion 31, and the frame plate portion 52A includes the coil 2 (particularly the end surfaces of the coil elements 2a, 2b) and the outer core portion 32 (particularly The insulation between the inner end face 32e) is enhanced.
  • one cylindrical portion 51A and one frame plate portion 52A are integrally formed.
  • Each tubular portion 51A is formed so as to cover the outer periphery of each inner core portion 31.
  • the assembly 10A includes two L-shaped core parts 315a and 315b in which the one cylindrical portion 51A, one frame plate portion 52A, and one inner core portion 31 are integrated.
  • the reactor 1A (assembly 10A) includes a base plate 54 that protrudes in parallel to both the axial direction of the coil elements 2a and 2b and the side-by-side direction of the coil elements 2a and 2b, on a rectangular frame-shaped frame plate portion 52A.
  • the base plate 54 is made of a rectangular flat plate material, and is perpendicular to the surface of the frame plate portion 52A (surface on the outer core portion 32 side) and protrudes from the upper edge of the frame plate portion 52A. It is erected. That is, the frame plate portion 52A and the base plate 54 are formed in an L shape (FIG. 3).
  • the base plate 54 is disposed parallel to the upper surface 32u so as to cover the upper surface 32u of the outer core portion 32 when the frame plate portion 52A and the outer core portion 32 are assembled (FIG. 3).
  • the part is disposed so as to protrude from the periphery of the upper surface 32u (FIG. 2). Then, the two corners of each base plate 54 (a total of four corners in the two base plates 54) function as engaging portions with the case 4A.
  • the case (reactor dedicated case) 4A is a rectangular box having a bottom 40 and a rectangular frame-shaped side wall 41 standing from the bottom 40 as shown in FIG.
  • the internal space of the case 4A is used as a storage space for the assembly 10A.
  • receiving portions 42 for receiving the corners of the base plate 54 are provided at four corners in the case 4A.
  • the receiving part 42 is a triangular columnar region formed so as to fill each corner in the case 4A, and a triangular plane is a support surface 420 that contacts the base plate 54. That is, the support surface 420 of the receiving portion 42 provided in the case 4A functions as an engaging portion with the insulator 5A (base plate 54) (FIG. 5).
  • such a reactor 1A includes a base plate 54 that protrudes from the periphery of the upper surface 32u of the outer core portion 32 when the assembly 10A of the coil 2, the magnetic core 3, and the insulator 5A is stored in the case 4A.
  • a base plate 54 protrudes from the periphery of the upper surface 32u of the outer core portion 32 when the assembly 10A of the coil 2, the magnetic core 3, and the insulator 5A is stored in the case 4A.
  • the combination of the coil 2 and the magnetic core 3 is the surface on the inner bottom surface 40i side of the case 4A in the combination, specifically, the lower surface 2d of the coil 2 and
  • the gap g is maintained between the lower surface 32d of the outer core portion 32 and the inner bottom surface 40i. That is, the combined body is suspended in the case 4A by the engagement of the base plate 54 and the receiving portion 42, and both the coil 2 and the magnetic core 3 are not in contact with the inner bottom surface 40i of the case 4A (floating). State).
  • the reactor 1A adjusts the gap g so that the coil 2 and the magnetic core 3 do not contact the case 4A. Therefore, the reactor 1A can reduce noise that may be generated due to contact between the case 4A (particularly the inner bottom surface 40i) and the assembly 10A (particularly the coil 2 or the magnetic core 3).
  • the reactor 1A is not able to transmit external vibration transmitted through the case 4A or vibration of the case 4A itself directly to the assembly 10A.
  • the vibration of the coil 2 cannot be transmitted directly to the case 4A. Noise caused by can be reduced. Therefore, the reactor 1A can reduce noise.
  • the reactor 1A uses the case 4A itself and the insulator 5A itself as members for forming the gap g, the number of parts does not increase and the number of assembly processes is small. Further, by adjusting the size (area) of the support surface 420 and sufficiently increasing the contact area with the corners of the base plate 54, the assembly 10A can be sufficiently supported.
  • a through-hole 54h (FIGS. 2, 4, and 5) is provided at the corner of the plate 54, an engagement protrusion 422 (FIGS. 1 to 3 and 5) is provided on the support surface 420, and the engagement protrusion 422 is formed in the through-hole. 54h is inserted (FIGS. 1, 3, and 5).
  • the insulator 10A can firmly support the assembly 10A with respect to the case 4A without using separate members such as screws, bolts, and adhesives. Therefore, the reactor 1A has a small number of parts and does not require a tightening process such as a screw or a bolt or an adhesive application / curing process. In particular, it is inferior in workability to apply the adhesive to the inner bottom surface 40i of the bottomed cylindrical case 4A in a uniform thickness, and omitting this work is highly industrially significant. Further, when the assembly 10A is stored in the case 4A, the assembly 10A can be accurately and easily positioned in the case 4A by using the through holes 54h and the engaging projections 422 as guides. From these points, the reactor 1A is excellent in assembling workability. Furthermore, the reactor 1A is unlikely to be displaced due to the engagement between the through hole 54h and the engagement protrusion 422.
  • the insulation between the coil 2 or the magnetic core 3 and the case 4A can be improved by adjusting the gap g, and a desired partial discharge start voltage or withstand voltage can be secured.
  • the sealing resin 100 (FIG. 3) is filled in the case 4A so that the sealing resin 100 is interposed between the assembly 10A and the case 4A, vibrations of the coil 2 and the magnetic core 3 are sealed. It can be absorbed to some extent by the stop resin 100. Further, external vibration and vibration transmitted to the case 4A can be absorbed to some extent by the sealing resin 100.
  • the vibration of the coil 2 and the magnetic core 3 is not directly transmitted to the case 4A due to the interposition of the sealing resin 100, so that the vibration transmitted to the case 4A can be mitigated, or the vibration of the case 4A or the like can be reduced.
  • the vibration transmitted to the braid 10A can be reduced. Therefore, this form can further reduce noise.
  • the presence of the sealing resin 100 makes it easier to support the assembly 10 than when it is a space.
  • the size of the gap g can be selected as appropriate.
  • the gap g is about 0.1 mm to 3 mm (here, about 2 mm).
  • the gap g is set such that the magnetic core 3 does not contact the case 4A even when vibration due to magnetostriction occurs.
  • the coil 2 or the magnetic core 3 and the case 4A are less likely to come into contact with each other, and noise can be easily reduced.
  • the insulation between the coil 2 and the magnetic core 3 and the case 4A is improved.
  • the gap g may be adjusted so that a creepage distance of a desired withstand voltage can be secured. The smaller the gap g, the smaller the bulk of the reactor 1A and the smaller the reactor 1A.
  • coil elements 2a and 2b and a connecting portion 2r are formed by one continuous winding 2w having no joint portion.
  • a part of the winding 2w that connects the two coil elements 2a and 2b is bent in a U-shape to form a connecting portion 2r, so that the winding directions of the two coil elements 2a and 2b are the same, and the two coil elements 2a , 2b are electrically connected in series.
  • a coated wire having an insulating coating made of an insulating material (typically polyamideimide) on the outer periphery of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof can be suitably used.
  • a covered rectangular wire having a conductor made of a copper rectangular wire is used.
  • Each coil element is manufactured by separate windings, and one end portions of the windings of each coil element are directly joined by welding, soldering, crimping, or the like, or a coil joined using a connecting member. it can.
  • the end face shape of the coil elements 2a and 2b is a rectangular frame here, but can be changed as appropriate (for example, an annular shape).
  • a terminal fitting (not shown) is typically connected to the conductor portion exposed by peeling off the insulation coating.
  • An external device such as a power source for supplying power to the coil 2 is connected to the coil 2 via the terminal fitting.
  • the inner core portion 31 of the magnetic core 3 is made of a plurality of core pieces 31m made of a soft magnetic material and a material having a relative permeability smaller than that of the core piece 31m, as shown in a broken-line circle in FIG. It is a laminate in which gap materials 31g are alternately laminated.
  • the core piece 31m and the gap material 31g are easy to handle, particularly when integrated with an adhesive, and the core piece 31m is made of a material that vibrates due to magnetostriction, and the gap material 31g is made of a material having high rigidity such as alumina. Even in such a case, it is expected that noise accompanying contact / non-contact between the core piece 31m and the gap material 31g can be reduced.
  • the core piece 31m and the gap material 31g are integrated with an adhesive tape or the like, it is easy to handle. Since the constituent resin (cylindrical part 51A) of the core parts 315a and 315b can function as a binding material for the laminate, it is possible to adopt a form in which no adhesive or adhesive tape is used.
  • the core piece 31m and the gap material 31g are integrated by an adhesive.
  • the outer core portion 32 is a core piece made of a soft magnetic material.
  • the inner core portion 31 has a rectangular parallelepiped shape
  • the outer core portion 32 has a columnar shape in which the upper surface 32u and the lower surface 32d (FIG. 3) have a dome shape (a deformed trapezoid shape in which the cross-sectional area decreases from the inner end surface 32e outward)
  • the shape of the inner core portion 31 (core piece 31m / gap material 31g) and the shape of the outer core portion 32 can be appropriately selected.
  • the size of the outer core portion 32 is set so that the surface on the installation side of the outer core portion 32 (FIG. 3: lower surface 32d) is flush with the surface on the installation side of the coil 2 (FIG. 3: lower surface 2d). It is adjusting.
  • the outer peripheral surface (particularly the lower surface 32d) of the outer core portion 32 protrudes from the outer peripheral surface of the inner core portion 31.
  • the surface on the installation side of the assembly 10A is mainly composed of the lower surfaces 32d of the two outer core portions 32 and the lower surface 2d of the coil 2.
  • the core pieces constituting the inner core portion 31 and the outer core portion 32 have a molded body using a soft magnetic powder typified by an iron group metal such as iron or an alloy thereof, an oxide containing iron, or an insulating coating.
  • a laminated plate body in which a plurality of magnetic thin plates (for example, an electromagnetic steel plate typified by a silicon steel plate) is laminated may be mentioned.
  • the molded body include a compacted body, a sintered body, and a composite material obtained by injection molding or cast molding a mixture including soft magnetic powder and resin.
  • each core piece is a powder compact of soft magnetic metal powder containing iron such as iron or steel.
  • the specific material of the gap material 31g is a mixture containing a nonmagnetic material such as alumina or unsaturated polyester, a nonmagnetic material such as polyphenylene sulfide (PPS) resin, and magnetic powder (for example, soft magnetic powder such as iron powder).
  • PPS polyphenylene sulfide
  • the gap material 31g is composed of a mixture containing PPS resin and iron powder (relative magnetic permeability: about 1.15).
  • each core piece constituting the magnetic core 3 has the same specification (compact compact) made of a uniform material, but the inner core portion 31 and the outer core portion 32 have different magnetic properties and The specifications can be different.
  • all the core pieces are composed of composite materials (the specifications of the core pieces are all the same), and the core pieces 31m of the inner core portion 31 and the outer core portion 32 have different forms and ratios of magnetic powder, (2) All core pieces have the same specifications (for example, a compacted body), and the core core 31m of the inner core portion 31 and the outer core portion 32 have different materials.
  • the inner core portion 31 The core pieces 31m may be a composite material, and the outer core portion 32 may be a compacted body or a laminated plate body with different specifications of the core pieces (the core pieces have the same material).
  • the forms of (1) and (2) above for example, assuming that the saturation magnetic flux density of the core piece 31m of the inner core portion 31> the saturation magnetic flux density of the outer core portion, the area of the location where the magnetic flux passes through the inner core portion 31 is It is easy to make it small and the reactor can be miniaturized.
  • the relative permeability of the composite material ⁇ the relative magnetic permeability of the powder compact.
  • the form (3) is less likely to be magnetically saturated due to the presence of the composite material even for large current applications, and the gap material 31g can be omitted.
  • the relative permeability of the outer core portion 32 is relatively high, the leakage magnetic flux in the outer core portion 32 can be easily reduced.
  • the composite material constituting the core piece 31m of the inner core portion 31 and the outer core portion 32 are both magnetic powder content: 40 vol% or more and 70 vol% or less, saturation magnetic flux density: Those satisfying 0.6T or more, the relative permeability: 5 to 50, preferably 10 to 30, and the relative permeability of the entire magnetic core: 5 to 50 are included.
  • the material and content of the magnetic powder for example, (a) the inner core portion has a high saturation magnetic flux density and the outer core portion has a low relative permeability, and (b) the inner core portion has a relative permeability.
  • the outer core portion has a high relative magnetic permeability and (c) the saturation magnetic flux density and the relative magnetic permeability of both the inner core portion and the outer core portion are the same.
  • the configuration (a) can reduce the size of the reactor as described above, and the configuration (b) can easily reduce the leakage magnetic flux in the outer core portion 32.
  • the form (c) is easy to prepare the raw material and is excellent in the productivity of the core piece.
  • the insulator 5A is a resin molded body in which the cylindrical portion 51A and the frame plate portion 52A are integrally formed of an insulating resin as described above, and the inner core portion 31 is also integrally formed by this resin.
  • the core parts 315a and 315b are formed by being held (FIG. 4).
  • the core parts 315a and 315b are members in which the inner core portion 31, a conventional inner bobbin (corresponding to the cylindrical portion 51A), and a conventional outer bobbin (corresponding to the frame plate portion 52A) are integrally molded.
  • the insulating resin functions as an insulating material between the coil 2 and the magnetic core 3 as well as a conventional insulator, and also functions as a binding material for components of the inner core portion 31.
  • the core parts 315a and 315b have the same shape, and when one core part 315a is rotated 180 ° in the horizontal direction, the other core part 315b is obtained. Therefore, the core parts 315a and 315b are easy to use because there is no need to consider directionality when assembling.
  • the core component 315a will be described as an example. Constituent elements common to both core parts 315a and 315b are denoted by the same reference numerals.
  • the core component 315a includes a cylindrical part 51A that covers the peripheral surface of the inner core part 31, and a frame plate part 52A on which the cylindrical part 51A is projected.
  • the cylindrical portion 51A may be interposed between the inner core portion 31 and the coil element 2a, and the shape, thickness, formation region, and the like can be selected as appropriate.
  • the cylindrical portion 51A covers the entire length of the inner core portion 31, and most of the cylindrical portion 51A is made of a thin resin, and a protrusion is appropriately provided on the surface thereof. These ridges support the inner peripheral surface of the coil element 2a.
  • the distal end side portion of the cylindrical portion 51A is formed by a flat surface that is thinner than the other portions and has no protrusions.
  • This thin flat portion functions as an insertion point into the short cylindrical portion 510A (the portion protruding from the frame plate portion 52A in parallel with the cylindrical portion 51A) provided in the other core component 315b.
  • each frame plate portion 52A is disposed in contact with each end surface of the coil elements 2a and 2b.
  • the other surface of each frame plate portion 52A is disposed in contact with the inner end surface 32e of each outer core portion 32.
  • each frame plate portion 52A is arranged orthogonal to the axial direction of the coil elements 2a and 2b.
  • Each of the frame plate portions 52A includes a support portion that can support the assembly 10A in a suspended state in the case 4A as described above.
  • the form of the support part can be selected as appropriate.
  • the base plate 54 protrudes so as to be orthogonal to the surface of the frame plate portion 52A (the contact surface with the outer core portion 32), that is, along the axial direction of the coil elements 2a and 2b.
  • the part is used as a support part.
  • the base plate 54 When at least a part of the base plate 54 is used as the support portion, as described above, the base plate 54 is formed so as to have a portion protruding from the peripheral edge of the outer core portion 32, thereby functioning as the support portion. .
  • the base plate 54 only needs to have a shape having such a protruding portion, and the planar shape may of course be other than a rectangular shape.
  • a tongue piece may be projected from a base plate 54 having an arbitrary planar shape (for example, a dome shape along the outer core portion 32), and the tongue piece may be used as a support portion.
  • the base plate 54 when used as a support portion as described above, if the contact area with the receiving portion 42 (support surface 420) of the case 4A is sufficiently wide, it is only necessary to place the base plate 54 on the receiving portion 42.
  • the braid 10A can be sufficiently supported.
  • the engaging groove into which the protrusion on the base plate 54 and the protrusion on the base plate 54 are fitted into the receiving portion 42 are fitted. It is good also as a form which provides both the through-hole 54h and the engagement protrusion 422, and a protrusion and an engagement groove
  • the shape of the through hole 54h / engagement protrusion 422 and the protrusion / engagement groove can be selected as appropriate.
  • it is circular, it may be a polygonal shape such as a rectangle or a triangle, or an irregular shape such as an ellipse. If the design likelihood of the through hole 54h and the engagement protrusion 422 and the design likelihood of the protrusion and the engagement groove are reduced as much as possible, it is expected that the assembly 10A will not rattle against the case 4A and noise can be reduced easily.
  • the number of engaging portions such as the through hole 54h and the engaging protrusion 422 can be appropriately selected. Here, a total of 4 sets are provided, but the number can be further increased or only 2 sets of diagonal positions can be provided.
  • the width of the frame plate portion 52A (length in the side-by-side direction of the coil elements 2a, 2b) is increased so as to sufficiently protrude from the edge of the coil 2 or the outer core portion 32, A configuration in which the side edge portion of the wide frame plate portion 52A is used as a support portion is exemplified.
  • a long groove into which the side edge portion of the frame plate portion 52A is fitted is provided on the side wall 41 of the case 4A.
  • the long groove is provided along the direction from the inner bottom surface 40i of the case 4A toward the opening of the case 4A, that is, orthogonal to the axial direction of the coil elements 2a and 2b, and the length thereof is adjusted as appropriate.
  • a gap g is provided between the assembly 10A and the inner bottom surface 40i of the case 4A.
  • the assembly 10A can be easily and accurately stored in the case 4A, and the assembly workability is excellent.
  • the arrangement position of the braid 10 is difficult to shift due to the engagement between the side edge and the long groove.
  • the side edge portion of the frame plate portion 52A and the long groove of the case 4A function as the engaging portions.
  • the gap g can be provided by adjusting the length of the protrusion.
  • each of the long groove of the frame plate portion 52A and the protrusion of the case 4A functions as an engaging portion.
  • the base plate 54 is not provided, and the bottom edge portion on the case 4A side of the frame plate portion 52A is extended to the case 4A side, and a fitting groove into which the bottom edge portion is fitted to the inner bottom surface 40i of the case 4A is provided. be able to.
  • the gap g is provided by adjusting the extending length of the bottom edge and the depth of the fitting groove.
  • the assembly 10A can be supported more firmly.
  • the base plate 54 is interposed between the connecting portion 2r of the coil 2 and the upper surface 32u of the outer core portion 32, and has a function of improving the insulation between the connecting portion 2r and the outer core portion 32.
  • the frame plate portion 52A includes a through hole 531 through which the inner core portion 31 of the other core component 315b can be inserted at a location where the short cylindrical portion 510A is provided.
  • the end face 31e here, the gap material 31g
  • the end face 31e and the outer core portion 32 The inner end surface 32e comes into contact.
  • the frame plate portion 52A includes an end surface covering portion 532 that covers the end surface 31e (here, a part of the end surface 31e) of the inner core portion 31 provided with the cylindrical portion 51A (FIG. 5).
  • the end surface covering portion 532 is interposed between the end surface 31e of the inner core portion 31 and the inner end surface 32e of the outer core portion 32 in the cylindrical portion 51A, and both surfaces 31e and 32e are directly Do not touch. That is, one inner core part 31 connected to one outer core part 32 is in direct contact with the outer core part 32, and the other inner core part 31 is connected via the end face covering part 532.
  • the end face covering portion 532 is made of an insulating resin, that is, a nonmagnetic material, and functions as a gap.
  • the frame plate portion 52A is provided on one surface thereof, is inclined according to the end surface shape of the coil elements 2a and 2b, is erected on the same surface, and is interposed between the coil elements 2a and 2b to be coil elements.
  • thermoplastic resins such as PPS resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), nylon 6, nylon 66, and polybutylene terephthalate (PBT) resin.
  • PPS resin is used.
  • the cylindrical part 51A and the frame plate part 52A are not integrated as in the insulator 5A, and the cylindrical part 51B and the frame plate part 52B can be separate members as in the insulator 5B shown in FIG.
  • the insulator 5B is also a separate member from the inner core portion (not shown in FIG. 6). 5 and 6, for ease of understanding, the side wall of the case 4A is omitted, and only the bottom 40 of the case 4A is cut away to partially show the bottom of the converter case 400 (described later).
  • the insulator 5B shown in FIG. 6 is substantially the same as the insulator 5A except that the cylindrical portion 51B and the frame plate portion 52B are independent members, and a detailed description thereof will be omitted.
  • one cylindrical portion 51B is configured by combining the pieces 511 and 512 having a cross section.
  • the divided pieces 511 and 512 are not in contact with each other, but may be provided with an engagement portion and coupled to each other.
  • the constituent materials of the divided pieces 511 and 512 can be reduced and the weight can be reduced.
  • the divided pieces 511 and 512 can be easily positioned with respect to each other.
  • each of the divided pieces 511 and 512 is provided with a through hole, but may be provided with no through hole.
  • the constituent materials of the divided pieces 511 and 512 can be reduced, the weight can be reduced, and when the sealing resin is provided, the contact area between the sealing resin and the inner core portion can be increased. And the inner core portion can be prevented more reliably.
  • the cylindrical portion 51B can be formed as an integral cylindrical body instead of the divided pieces 511 and 512. In this case, the number of parts can be reduced. Or, a configuration including a member in which one frame plate portion 52B and one divided piece 511 are integrated and a member in which the other frame plate portion 52B and the other divided piece 512 are integrated is provided. You can also In this case, the number of parts is small and the number of assembly steps can be reduced.
  • Each frame plate portion 52B has a shape obtained by removing the cylindrical portion 51A and the end surface covering portion 532 from the above-described frame plate portion 52A (FIG. 4), and has through holes 531 through which the two inner core portions 32 are respectively inserted. Have two. Further, a rectangular base plate 54 that protrudes in the axial direction of the coil from the surface in contact with the outer core portion is provided. Further, through holes 54h are provided at two corners of the base plate 54. Like the above-described insulator 5A (FIG. 4), the insulator 5B is also inserted into the assembly 10A (FIG. 3) in the same manner as the above-described insulator 5A (FIG. 4) by inserting the protrusions 422 provided in the receiving portion 42 of the case through the respective through holes 54h. Can be maintained in a suspended state.
  • the case 4A is used for mechanical protection of the assembly 10A, protection from the environment, a heat radiation path (especially in the case of metal), a magnetic shield (especially in the case of metal), and the like.
  • Typical materials include metals such as aluminum and alloys thereof, magnesium and alloys thereof, copper and alloys thereof, silver and alloys thereof, iron and austenitic stainless steel.
  • aluminum, magnesium, and alloys thereof are lightweight and can be expected to have a shielding function. Aluminum and its alloys are also excellent in heat dissipation.
  • case 4A can be selected as appropriate.
  • the size can be reduced. As shown in FIG. 1, a rectangular shape is excellent in manufacturability.
  • the case 4A is integrally formed with the main body 410 of the converter case 400 in which a circuit board (not shown) including a semiconductor element and the like are housed in addition to the assembly 10A as shown in FIG.
  • a frame-like side wall 41 is provided at the bottom of the main body 410 to divide the space in the main body 410.
  • the case 4A includes a receiving portion 42 inside thereof as shown in FIGS. 1 to 3 and FIG.
  • the shape of the receiving part 42 is not particularly limited.
  • a triangular prism shape is used, but a rectangular parallelepiped provided so as to be continuous with two corners or a rectangular frame provided so as to be continuous with four corners may be used.
  • the contact area with the base plate 54 is increased by increasing the size of the base plate 54, and the assembly 10A can be supported more stably.
  • the triangular prism shape is used as in this example, the dead space of the rectangular case 4A is used for the receiving portion 42, and thus the case 4A can be downsized.
  • the column-shaped receiving part 42 or together with the receiving part 42 it can be configured to have a long groove or a ridge as described above.
  • the reactor 1A can be configured to include a lid (not shown) that covers the opening of the case 4A. It is expected that noise can be further reduced by having a lid. When a lid is provided, the protrusion 422 can also be used for positioning the lid.
  • the case 4 may be filled with the sealing resin 100 (FIG. 3). Sealing resin 100 reduces vibration, protects the assembly 10A mechanically and protects from the external environment (improves corrosion resistance), and depending on the material, improves heat dissipation, further reduces noise, further reduces vibration Etc.
  • the filling region of the sealing resin 100 can be appropriately selected.
  • the sealing resin 100 can be provided only between the bottom surface of the assembly 10A (the lower surface 2d of the coil 2 and the lower surface 32d of the outer core portion 32) and the inner bottom surface 40i of the case 4A, that is, only in the gap g. .
  • the sealing resin 100 is interposed between the bottom surface of the assembly 10A and the inner bottom surface 40i of the case 4A, so that vibration can be reduced as described above, or the assembly 10A can be suspended by the insulator 5A.
  • the state can be reinforced by the sealing resin 100.
  • the sealing resin 100 can be provided from the inner bottom surface 40i of the case 4A to the contact point between the base plate 54 and the case 4A (here, the engagement point between the through hole 54h and the protrusion 422).
  • the engaging portion between the base plate 54 and the case 4A can be fixed by the sealing resin 100. Therefore, this form can more firmly maintain the suspended state of the braid 10A by the insulator 5A. Furthermore, when the protrusion 422 is completely embedded in the sealing resin 100, the suspended state can be maintained more firmly. Also, as shown by the one-dot chain line in FIG.
  • the assembly 10A can be well protected from the external environment. it can. In this case, if the end of the winding 2w is exposed from the sealing resin 100, the end of the winding 2w and the terminal fitting can be easily joined. After joining the end of the winding 2w and the terminal metal fitting, this joint location can also be embedded in the sealing resin 100.
  • the sealing resin 100 examples include insulating resins such as an epoxy resin, a urethane resin, and a silicone resin. Further, when a sealing resin 100 containing a filler that has excellent insulating properties and heat dissipation properties is used as the sealing resin 100, heat dissipation properties (thermal conductivity) and insulation properties can be improved. When the sealing resin 100 is provided, it is also possible to adjust the material and thickness (for example, to use a material having elasticity capable of absorbing vibration due to magnetostriction, or to have a thickness capable of absorbing vibration due to magnetostriction, etc. It is expected that noise can be effectively reduced.
  • insulating resins such as an epoxy resin, a urethane resin, and a silicone resin.
  • the reactor 1A can be manufactured by the steps of manufacturing the assembly 10A ⁇ accommodating the assembly 10A in the case 4 ⁇ filling the sealing resin 100 as appropriate.
  • core parts 315a and 315b and an outer core part 32 are prepared.
  • the core components 315a and 315b can be manufactured by insert molding using a laminated columnar body of the core piece 31m and the gap material 31g as a core.
  • the core components 315a and 315b and the coil 2 are assembled, and the outer core portion 32 is further assembled to form the magnetic core 3 having an annular closed magnetic path.
  • the assembly 10A is formed by this process.
  • the inner core portion 31, the outer core portion 32, and the insulator 5B are prepared, the cylindrical portion 51B is arranged on the inner core portion 31, and the coil 2 is assembled.
  • the assembly 10A is formed by assembling the frame plate portion 52B and the outer core portion 32.
  • the assembly 10A can be easily and accurately stored in the case 4A.
  • the reactor 1A that does not include the sealing resin 100 can be manufactured.
  • the obtained reactor 1A has a space between the bottom surface of the assembly 10A (the lower surface 2d of the coil 2 and the lower surface 32d of the outer core portion 32) and the inner bottom surface 40i of the case 4A.
  • the reactor 1A including the sealing resin 100 can be manufactured by appropriately filling and curing the sealing resin 100 in the case 4.
  • the sealing resin 100 is disposed so that at least the sealing resin 100 is interposed between the bottom surface of the assembly 10A (the lower surface 2d of the coil 2 and the lower surface 32d of the outer core portion 32) and the inner bottom surface 40i of the case 4A. It is desirable to adjust the amount. Note that the end of the winding 2w and the terminal fitting can be connected at any time.
  • the maximum current (direct current) is about 100A to 1000A
  • the average voltage is about 100V to 1000V
  • the operating frequency is about 5kHz to 100kHz, typically electric vehicles and hybrid vehicles. It can utilize suitably for the component of the vehicle-mounted power converter device.
  • the reactors of the first and second embodiments can be used, for example, as a component part of a converter mounted on a vehicle or the like, or a component part of a power conversion device including the converter.
  • a vehicle 1200 such as a hybrid car or an electric car 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. Motor (load) 1220.
  • the motor 1220 is typically a three-phase AC motor, which drives the wheel 1250 when traveling and functions as a generator during regeneration.
  • the vehicle 1200 includes an engine in addition to the motor 1220.
  • FIG. 8 although an inlet is shown as a charging location of the vehicle 1200, a form including a plug may be adopted.
  • 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 power to the inverter 1120.
  • 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 power to the motor 1220. 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 tends to prevent the change of the current to flow through the circuit.
  • the reactor L includes the reactors of the first and second embodiments.
  • Vehicle 1200 is connected to converter 1110, power supply converter 1150 connected to main battery 1210, sub-battery 1230 as a power source for auxiliary devices 1240, and main battery 1210.
  • Auxiliary power converter 1160 for converting high voltage to 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 converters 1150 for power feeding devices 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 1A and the like of the first and second embodiments, and a reactor whose size and shape are appropriately changed can be used. Further, the reactor 1A of the first and second embodiments can be used for a converter that performs conversion of input power and that only performs step-up or only performs step-down.
  • the reactor of the present invention and the assembly for the reactor of the present invention include an in-vehicle converter (typically a DC-DC converter) mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, and a fuel cell vehicle. It can utilize suitably for the component of power converters, such as a converter of an air conditioner.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Dc-Dc Converters (AREA)

Abstract

La présente invention porte sur un réacteur (1A) qui permet de réduire un bruit et une aptitude au travail d'ensemble est supérieure. Le réacteur (1A) de la présente invention comprend : une bobine cylindrique (2) ayant un fil (2w) enroulé autour de celle-ci; des noyaux magnétiques (3) ayant des parties positionnement de la bobine (2); des isolants (5A) comprenant en outre des parties logement qui sont positionnées entre la bobine (2) et les parties de positionnement de la bobine (2) et des parties exposées qui sont positionnées en contact avec des faces d'extrémité de la bobine (2); et un boîtier cylindrique (4A) ayant un fond solide, qui loge un ensemble (10A) de la bobine (2) les noyaux magnétiques (3) et les isolants (5A). Un intervalle (g) est disposé entre une face inférieure intérieure (40i) du boîtier (4A) et à la fois la bobine (2) et les noyaux magnétiques (3). Les parties exposées des isolants (5A) comprennent en outre des parties de support (plaques de base (54) dans le présent exemple) qui portent l'union de la bobine (2) et des noyaux magnétiques (3) de telle sorte que l'intervalle (g) est formé par rapport au boîtier (4A). L'ensemble (10A) est maintenu par les parties de support des isolants (5A) dans un état suspendu dans le boîtier (4A), permettant une réduction de bruit.
PCT/JP2013/065559 2012-08-07 2013-06-05 Réacteur, ensemble pour réacteur, convertisseur et dispositif de conversion d'énergie WO2014024555A1 (fr)

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JP2012175360A JP2014036058A (ja) 2012-08-07 2012-08-07 リアクトル、リアクトル用の組物、コンバータ、及び電力変換装置
JP2012-175360 2012-08-07

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JP2015198205A (ja) * 2014-04-02 2015-11-09 株式会社タムラ製作所 リアクトル
WO2017141784A1 (fr) * 2016-02-18 2017-08-24 株式会社オートネットワーク技術研究所 Structure de circuit et boîte à bornes électrique
JP2018186281A (ja) * 2018-06-26 2018-11-22 株式会社タムラ製作所 リアクトル

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JP5881015B2 (ja) * 2012-12-28 2016-03-09 株式会社オートネットワーク技術研究所 リアクトル、コンバータ、および電力変換装置
JP6420122B2 (ja) * 2014-11-05 2018-11-07 株式会社ケーヒン 電力変換装置
JP2016127109A (ja) * 2014-12-26 2016-07-11 ダイキン工業株式会社 リアクトルの冷却構造
JP6459141B2 (ja) * 2015-02-25 2019-01-30 住友電装株式会社 リアクトル
KR101675401B1 (ko) * 2015-05-12 2016-11-14 주식회사 코아전기 전자파 장해 필터용 리액터 및 그것을 이용한 전자파 장해 필터
JP6429933B2 (ja) * 2017-04-20 2018-11-28 三菱電機株式会社 電磁機器の固定構造体
JP6758262B2 (ja) * 2017-08-10 2020-09-23 三菱電機株式会社 静止誘導器
JP6947071B2 (ja) * 2018-02-13 2021-10-13 株式会社オートネットワーク技術研究所 インダクタ、基板付きインダクタ及び電気接続箱
JP2020167194A (ja) * 2019-03-28 2020-10-08 株式会社豊田自動織機 電気機器
JP7146178B2 (ja) * 2019-05-24 2022-10-04 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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WO2017141784A1 (fr) * 2016-02-18 2017-08-24 株式会社オートネットワーク技術研究所 Structure de circuit et boîte à bornes électrique
JP2018186281A (ja) * 2018-06-26 2018-11-22 株式会社タムラ製作所 リアクトル

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