WO2014115672A1 - Réacteur, convertisseur et dispositif de conversion de puissance - Google Patents

Réacteur, convertisseur et dispositif de conversion de puissance Download PDF

Info

Publication number
WO2014115672A1
WO2014115672A1 PCT/JP2014/050918 JP2014050918W WO2014115672A1 WO 2014115672 A1 WO2014115672 A1 WO 2014115672A1 JP 2014050918 W JP2014050918 W JP 2014050918W WO 2014115672 A1 WO2014115672 A1 WO 2014115672A1
Authority
WO
WIPO (PCT)
Prior art keywords
coil
core
resin
end surface
insulating member
Prior art date
Application number
PCT/JP2014/050918
Other languages
English (en)
Japanese (ja)
Inventor
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
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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 WO2014115672A1 publication Critical patent/WO2014115672A1/fr

Links

Images

Classifications

    • 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
    • H01F27/02—Casings
    • H01F27/022—Encapsulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
    • H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
    • H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load

Definitions

  • the present invention relates to a reactor used as a component of a power conversion device such as an in-vehicle DC-DC converter mounted on a vehicle such as a hybrid vehicle, a converter including the reactor, and a power conversion device including the converter. Is.
  • the present invention relates to a reactor having excellent productivity.
  • Patent Document 1 discloses a reactor used in a converter mounted on a vehicle such as a hybrid vehicle.
  • the reactor includes a coil having a pair of cylindrical coil elements, a pair of intermediate cores (inner core parts) inserted and arranged in each coil element, and a pair of end cores (outer cores) in which no coils are arranged.
  • Part) in a ring shape a bobbin interposed between the coil and the magnetic core to enhance the insulation, and a resin coating part (resin part) covering the periphery of the bobbin.
  • Each intermediate core is composed of an assembly of a plurality of core pieces and a gap material, and each end core is composed of a core piece.
  • the bobbin includes two cylindrical bobbins and two frame bobbins.
  • Each cylindrical bobbin is a cylindrical member interposed between one coil element and one inner core part inserted and arranged in the coil element, and the outer peripheral surface of the columnar inner core part is Cover the entire circumference along the circumferential direction.
  • Patent Document 1 discloses a form in which each cylindrical bobbin is configured in a cylindrical shape by combining a pair of divided pieces. With this configuration, the cylindrical bobbin can be easily arranged on the outer periphery of the inner core portion.
  • Each frame-shaped bobbin is a glasses-type flat plate member having two through-holes through which two inner core portions are inserted, and between the end faces of both coil elements arranged side by side and one outer core portion. Intervened.
  • the frame-shaped bobbin is a flat plate member, it is difficult to position the frame-shaped bobbin with respect to the end surface of the coil accurately and in a short time. From these points, in a reactor having a conventional bobbin, manufacturing time tends to be long, and it is difficult to further improve productivity.
  • the cylindrical bobbin has an annular portion that covers the outer periphery of the inner core portion over the entire circumference thereof, and the frame-shaped bobbin covers the entire end surface of the two coil elements arranged side by side.
  • the manufacturing time is increased in the following points.
  • the amount of material used increases and the manufacturing cost may increase.
  • one of the objects of the present invention is to provide a reactor having excellent productivity.
  • Another object of the present invention is to provide a converter including a reactor having excellent productivity, and a power converter including the converter.
  • the present invention achieves the above object by setting the shape of a member interposed between the coil and the magnetic core to enhance the insulation between the coil and the magnetic core to a specific shape.
  • the reactor of the present invention is a magnetic coil having a cylindrical coil formed by winding a winding in a spiral, an inner core portion disposed inside the coil, and an outer core portion where the coil is not disposed, And an insulating member interposed between the coil and the magnetic core.
  • the insulating member includes an end surface interposed portion interposed between one annular end surface of the coil and the outer core portion, and an inner interposed portion interposed between the coil and the inner core portion to position the both.
  • the part is integrally formed.
  • the end surface interposition portion is disposed only along a part of the circumferential direction along the annular end surface, and the inner interposition portion is part of the circumferential direction along the cylindrical inner peripheral surface of the coil. Placed only on.
  • the reactor of the present invention is excellent in productivity.
  • FIG. 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 which concerns on embodiment of this invention which provides the converter which concerns on embodiment of this invention.
  • the reactor which concerns on embodiment of this invention has the cylindrical coil formed by winding a coil
  • the insulating member includes an end surface interposed portion interposed between one annular end surface of the coil and the outer core portion, and an inner interposed portion interposed between the coil and the inner core portion to position the both.
  • the part is integrally formed.
  • the said end surface interposition part is arrange
  • the inner interposition part is disposed only along a part of the circumferential direction along the cylindrical inner peripheral surface of the coil.
  • the “inner core portion disposed inside the coil” in the reactor of the present embodiment refers to a region of the magnetic core that is substantially disposed inside the coil, and “an outer core portion where no coil is disposed”.
  • the term “region” in the magnetic core refers to a region where the coil is not substantially disposed.
  • the magnetic core is composed of a plurality of core pieces (when there is no gap material; however, an air gap is allowed), or when it is composed of a plurality of core pieces and at least one gap material,
  • the core piece and gap material including a portion arranged inside the coil are also included in the inner core part.
  • the core piece when the central part of one core piece (most part of the core piece) is arranged inside the coil and the end of the core piece and the vicinity thereof are exposed from the coil, the core piece is , Considered as the inner core. Most of the assembly of the plurality of core pieces (typically, an integrated object fixed with an adhesive or an adhesive tape) is disposed inside the coil, and the remaining portion (for example, the assembly of the plurality of core pieces among the plurality of core pieces). When all or a part of the core piece constituting the end portion of the core is exposed from the coil, this assembly is regarded as the inner core portion. In addition, this aggregate
  • the above-mentioned insulating member can be said to be a member in which an end surface intervening portion that functions as a conventional frame-shaped bobbin and an inner intervening portion that functions as a cylindrical bobbin are integrated.
  • the reactor of the present embodiment can omit the conventional cylindrical bobbin, so that the number of parts is small and the number of assembly steps can be reduced.
  • the inner interposed portion can be easily positioned with respect to the coil and the inner core portion, and the inner interposed portion is positioned, the end surface interposed portion integrated with the inner interposed portion can be automatically positioned.
  • the reactor of the form is excellent in assembling workability. Therefore, the reactor of this embodiment can aim at shortening of manufacturing time and can improve productivity.
  • the shape of the above-mentioned insulating member is similar to the shape in which a part of the annular portion of the conventional frame bobbin is cut away and opened. Because of this shape, when the reactor further includes a resin portion that covers the combination of the coil and the magnetic core, it can exist between the coil and the inner core portion from the opened portion or the like when the constituent resin is filled. Gas can be easily discharged out of the combination, and the degassing time can be shortened. If the inner intervening portion is made smaller, the deaeration time can be further shortened. Further, since the deaeration can be sufficiently performed, the constituent resin of the resin part can be filled to every corner, and the resin part can be molded with high accuracy. From these points, even when the reactor of the present embodiment includes a resin portion, the manufacturing time can be shortened, productivity can be improved, and a resin portion excellent in molding accuracy can be provided.
  • the amount of material used for the above-mentioned insulating member can be made higher than that of the conventional bobbin. It can be effectively reduced. From this point, it is expected that the reactor of the present embodiment can reduce the amount of material used for the insulating member and can reduce the cost.
  • the reactor of this embodiment it is provided with the resin part which covers the combination of the above-mentioned coil and the above-mentioned magnetic core, the above-mentioned end face interposition part is not arranged between the above-mentioned annular end face and the above-mentioned outer core, and the above The form by which the resin which comprises the said resin part is filled in the area
  • the above-mentioned form is easy to deaerate when filling the constituent resin of the resin part as described above, and is excellent in productivity.
  • the above-described configuration can be applied to the resin between the coil and the inner core portion, between the coil and the outer core portion, and between the coil and the magnetic core and the insulating member.
  • the constituent resin of the part is interposed. Therefore, the said form WHEREIN: A coil, a magnetic core, and an insulating member are firmly integrated by the resin part, and it can be said that rigidity is high as the whole reactor. Due to the high rigidity, the above-described form is difficult to vibrate and noise can be reduced.
  • the said inner core part is an integral thing comprised from the composite material containing magnetic body powder and resin, and the said insulating member is between the said inner core part and the said outer core part.
  • an inter-core interposition part that is positioned at a constant interval between the two.
  • the inner core part is an integral body made of the composite material, the above-described form can further reduce the number of parts and the number of assembly steps. Since the composite material can easily adjust the magnetic properties depending on the type and content of the magnetic powder, the inner core portion made of the composite material is used as a constituent member to provide a magnetic core having various magnetic properties. A reactor can be easily manufactured. In addition, since the insulating member includes the inter-core interposition part, the above-described configuration allows the insulating member to easily and accurately provide a predetermined interval between the inner core part and the outer core part. Can be easily positioned and has excellent assembly workability. From these points, the above form is more excellent in productivity.
  • the constituent resin of the resin portion is also filled between the inner core portion and the outer core portion, and this constituent resin is bonded to both core portions.
  • the compacted body can easily form various three-dimensional shapes as compared with the laminated body of electromagnetic steel sheets, the above-mentioned form is excellent in productivity because it is easy to produce various shapes of inner core parts.
  • the end surface interposed part includes a positioning part for positioning the outer core part.
  • the above embodiment can easily position the outer core part with respect to the end face interposition part and is excellent in assembling workability, so that productivity can be improved.
  • the inner interposition part may have a notch or a form having a through hole.
  • the above form can further reduce the amount of material used for the insulating member.
  • the above-mentioned resin part when the above-mentioned resin part is provided, the above-mentioned notches and through holes can be used for resin flow paths and degassing passages of the resin part to shorten the filling time and the degassing time. Can do.
  • the resin portion can be molded with high accuracy. Therefore, when providing the above-mentioned resin part, the form which provides the said notch and a through-hole is excellent in the formation workability
  • the reactor of the present embodiment can be suitably used as a component part of a converter.
  • the converter of the present embodiment includes the reactor of the present embodiment.
  • the converter of this embodiment is excellent in productivity by making the reactor of this embodiment excellent in productivity into a structural member.
  • the converter of the present embodiment can be suitably used as a component part of a power conversion device.
  • the power conversion device of the present embodiment includes the converter of the present embodiment.
  • the power conversion device of the present embodiment is excellent in productivity and can be suitably used for in-vehicle components and the like by using the converter of the present embodiment including the reactor of the present embodiment that is excellent in productivity as a constituent member. .
  • the reactor 1 includes a cylindrical coil 2 formed by spirally winding a winding 2w, a magnetic core 3 disposed inside and outside the coil 2 to form a closed magnetic circuit, and between the coil 2 and the magnetic core 3.
  • the insulating member 5 is interposed, and is typically used by being installed on an installation target such as a cooling base.
  • the coil 2 is mainly composed of a pair of cylindrical coil elements 2a and 2b.
  • the magnetic core 3 is formed by combining a columnar inner core portion 31, 31 inserted and arranged inside each of the coil elements 2a, 2b and a columnar outer core portion 32, 32 where the coil elements 2a, 2b are not disposed.
  • One of the features of the reactor 1 is the shape of the insulating member 5 and the number of parts thereof.
  • the insulating member 5 is composed of two parts, an insulating member 5A disposed on one end surface side of both coil elements 2a and 2b and an insulating member 5B disposed on the other end surface side of both coil elements 2a and 2b.
  • the Both insulating members 5A and 5B have the same shape, and the arrangement position and the arrangement direction of the coil 2 and the magnetic core 3 with respect to the combined body 10 are different.
  • the insulating members 5A and 5B are both a portion (end surface interposed portion 52) interposed between the coil 2 and the outer core portion 32 and a portion interposed between the coil 2 and the inner core portion 31 ( The inner interposition part 54) is integrally formed.
  • the inner interposition part 54 is integrally formed.
  • the coil 2 includes a pair of coil elements 2a and 2b formed by spirally winding one winding 2w, and both coil elements 2a and 2b. And a connecting portion 2r to be connected.
  • Each of the coil elements 2a and 2b is a hollow cylindrical body having the same number of turns.
  • the coil elements 2a and 2b are arranged in parallel (side by side) so that their axial directions are parallel to each other, and are electrically connected in series.
  • the end face shapes of the coil elements 2a and 2b are both substantially rectangular shapes obtained by rounding the rectangular corner portions.
  • the magnetic core 3 includes a pair of inner core portions 31 and 31 and a pair of outer core portions 32 and 32 as shown in FIGS.
  • Each of the inner core portions 31 and 31 is a rectangular parallelepiped integral member (one core piece) with rounded corners, and is inserted and arranged in the coil elements 2a and 2b arranged side by side, thereby arranging the coil 2.
  • Each of the outer core parts 32, 32 is a rectangular parallelepiped monolithic object having one inner end face 32 (FIGS. 2 and 3) sufficiently larger than the total area of the end faces 31e, 31e of the inner core parts 31, 31 (one A core piece) and a portion exposed from the coil 2.
  • the insulating member 5 is a member that improves the insulation between the coil 2 and the magnetic core 3, and is made of an insulating material.
  • Specific examples of the insulating material include polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, and liquid crystal polymer (LCP).
  • the insulating member 5 includes an end surface interposed portion 52 interposed between the annular end surface of the coil 2 and the inner end surface 32e of the outer core portion 32, and the inner peripheral surface of the coil 2 and the outer peripheral surface of the inner core portion 31.
  • the inner interposition part 54 interposed between the two is a main component, and these are integrally formed.
  • the end face interposition part 52 is a plate-shaped member having a specific shape
  • the inner interposition part 54 is a band-like member protruding from the plate-like member.
  • the end surface interposed portion 52 is disposed only in a part of the circumferential direction with respect to the annular end surface of the coil 2, and the other end portion of the annular end surface is not disposed with the end surface interposed portion 52. . That is, when viewed in the circumferential direction of the coil elements 2a and 2b, the end surface interposed portion 52 does not have an annular portion that continuously covers the annular end surface, and is disposed on the entire circumference of the annular end surface. It is a non-annular member that cannot be covered over. In other words, the end surface interposition part 52 has a shape in which both of two rings included in the conventional frame bobbin are cut out.
  • the end face interposition part 52 is arranged only in a part of the circumferential direction with respect to the end face of one coil element 2a, and is part of the circumferential direction with respect to the end face of the other coil element 2b.
  • the end face intervening portion 52 is not disposed in any other portion in the circumferential direction. Therefore, in the reactor 1 in which the end face interposition part 52 is arranged, the other part in the circumferential direction of the end faces of both coil elements 2a and 2b and a part of the inner end face 32e of the outer core part 32 are exposed from the end face interposition part 52. It is in the state.
  • the inner interposition part 54 is arranged only in a part of the circumferential direction with respect to the cylindrical inner peripheral surface of the coil 2, and the inner interposition part 54 is arranged on the other part of the cylindrical inner peripheral surface.
  • the inner interposed portion 54 has an annular portion that continuously covers the circumferential direction of the cylindrical coil elements 2a and 2b when viewed in the axial direction of the coil elements 2a and 2b (inner core portions 31 and 31). It is not a non-annular member.
  • the inner interposition part 54 has a shape in which a part of the conventional cylindrical bobbin in the circumferential direction is cut away.
  • the inner interposition part 54 is arranged only in a part in the circumferential direction with respect to the inner peripheral surface of the square cylindrical shape with rounded corners in the coil element 2a and the outer peripheral surface of the one inner core part 31.
  • a part (inner interposition part 54a), a rectangular cylindrical inner peripheral surface with rounded corners in the coil element 2b, and an outer peripheral surface of the other inner core part 31 are arranged only in a part in the circumferential direction.
  • a portion (inner intervening portion 54b) is not arranged in the other part of the inner peripheral surface of the coil element 2a and the other part of the outer peripheral surface of the one inner core part 31.
  • the inner interposed portion 54b is not disposed in the other portion of the inner peripheral surface of the coil element 2b and the other portion of the outer peripheral surface of the other inner core portion 31. Therefore, in the reactor 1 in which the end surface interposition part 52 is arranged, the other part in the circumferential direction of the inner peripheral surface of both the coil elements 2a and 2b and the other part of the outer peripheral surface of the inner core part 31 are so-called from the end surface interposition part 52. It is in an exposed state.
  • the end surface interposition part 52 has a generally H-shaped member (in FIG. 1 (B) or the like, H is to the right or left as shown in FIGS. 1 (B), 2 (A), and 2 (B). 90 ° rotated state).
  • One surface of the end surface interposed portion 52 (the left surface in FIGS. 1B and 2A and the surface disposed on the outer core portion 32 side, hereinafter referred to as the core surface) is a uniform plane. Yes, the other surface (the left surface in FIG. 2B and the surface disposed on the coil 2 (FIG.
  • the coil surface is spiral along the end surface of the coil 2 Is an inclined surface provided with an inclination.
  • the insulating member 5 end surface interposition part 52
  • the entire coil surface may be a plane that does not have the inclination and is orthogonal to the axial direction of the coil elements 2a and 2b.
  • the end surface intervening portion 52 includes a central band portion 52c and an upper line portion 52u and a lower band portion 52d which are respectively provided so as to be orthogonal to the central axis of the central band portion 52c. And has a generally line-symmetric shape about the central axis of the central belt portion 52c.
  • the end surface interposition part 52 is two symmetrically positioned among the four corners arranged on the outside. Each corner (here, the upper corner) is cut out.
  • the central band 52c is arranged so as to cross the end surfaces of the two coil elements 2a, 2b arranged side by side, and the coil surface of the central band 52c is one end surface of each of the coil elements 2a, 2b. It is arranged in contact with the part.
  • the upper line portion 52u and the lower band portion 52d are arranged along the horizontal direction of the two coil elements 2a and 2b and along the contours of the end surfaces 31e and 31e of the inner core portions 31 and 31, respectively.
  • the lower belt portion 52d is provided such that its coil surface is in contact with a part of the end surface of each coil element 2a, 2b.
  • the upper line portion 52u substantially has no coil surface and does not contact the end surfaces of the coil elements 2a and 2b.
  • the upper line portion 52u functions as a connection location of the inner interposition portion 54 and the inter-core interposition portion 56 described later.
  • one side disposed on the adjacent side of the coil elements 2a, 2b is the central band portion.
  • the lower side band 52d covers the lower side and the outer corner formed by the one side and a part of the outer side that is perpendicular to the lower side and forms the outer corner.
  • a T-shaped portion formed by the central band portion 52c and the lower band portion 52d is interposed between the end surfaces of the coil elements 2a and 2b and the inner end surface 32e of the outer core portion 32.
  • the end face interposition part 52 can have various shapes as long as the insulation distance between the coil 2 and the outer core part 32 can be secured.
  • a central belt portion 52c and a lower belt portion 52d are provided along the annular end face so as to cover about 50 area% of the annular end face of each coil element 2a, 2b.
  • the width of the central band 52c is set to be twice or more the width of the winding 2w, and the width of the lower band 52d is approximately the same as the width of the winding 2w.
  • the width of the lower band 52d Can be made thinner than the width of the winding 2w.
  • the end surface interposition portion 52 preferably has a shape that allows the coil surface to cover 30 area% or more with respect to the total area of the annular end surfaces of the coil 2.
  • the smaller the coil surface of the end surface interposed portion 52 the more exposed portions of the coil 2 and the inner core portion 31 from the insulating member 5 can be made.
  • the end surface interposition portion 52 preferably has a shape that allows the coil surface to cover 70 area% or less with respect to the total area of the annular end surfaces of the coil 2.
  • the end surface intervening portion 52 can be formed by omitting the central band portion 52c and the upper line portion 52u, and only the lower band portion 52d.
  • the end face intervening portion 52 has a so-called (shallow depth) U-shape.
  • the length of the lower belt portion 52d is shortened (for example, the length covering only one lower side of the four sides forming the end faces of the rectangular frames of the coil elements 2a and 2b), or the upper line portion 52u can be a strip having a width approximately equal to the width of the winding 2w, such as the lower band 52d.
  • the connection portion 2r of the coil 2 and the outer core portion 32 do not come into contact with each other due to the presence of the upper line portion 52u, and the insulation between them can be improved.
  • the location where the coil 2 is not covered by the insulating member 5 can be selected as appropriate, but the location outside the coil 2 (here, the location outside the two coil elements 2a and 2b, that is, not adjacent to each other). It is preferable to provide the insulating member 5 so that the side portion is not covered with the insulating member 5.
  • the constituent resin of the resin portion 100 is easily filled, and the filling workability is excellent.
  • the inner interposition part 54 protrudes from a part along the inner peripheral edge of the annular end face in the coil elements 2a and 2b (FIG. 2 (C)) among the peripheral edges of the end face interposition part 52. It is a strip.
  • both the inner interposition part 54a inserted and arranged in the coil element 2a and the inner interposition part 54b inserted and arranged in the coil element 2b both pass from the upper line part 52u of the end face interposition part 52 through the central band part 52c.
  • a C-shape is provided along the lower belt portion 52d.
  • the protruding length of the inner interposition part 54 is preferably about 1% or more and 10% or less with respect to the entire length of the inner core part 31.
  • the protruding length of the inner interposition part 54 is about 6% with respect to the entire length of the inner core part 31.
  • the end surface interposition portion 52 is only the lower band portion 52d, and the lower band portion 52d has the above-described C-shaped inner interposition portions 54a and 54b integrally formed, or the end surface interposition portion 52 is formed as the central band portion.
  • the insulating member 5 includes an inter-core interposition part 56 that is interposed between the inner core part 31 and the outer core part 32 and positions the both at a constant interval.
  • the inter-core interposition part 56 is a protrusion standing from an inner peripheral surface continuous with the inner interposition part 54 in the end face interposition part 52.
  • the protrusions are rectangular plate-shaped, and are provided at the opposing positions of the upper line portion 52u and the lower band portion 52d.
  • an inter-core interposition part 56a projecting from the lower band part 52d and an inter-core interposition part 56c projecting from the upper line part 52u are arranged. Also, between the rectangular end surface 31e of the other inner core portion 31 disposed in the other coil element 2b and the inner end surface 32e of the one outer core portion 32, there is an inter-core protruding from the lower belt portion 52d. An interposition part 56b and an inter-core interposition part 56d protruding from the upper line part 52u are arranged.
  • the inter-core interposition part 56 can be used for stopping when the insulating member 5 is arranged in the assembly of the coil 2 and the inner core parts 31, 31, the insulating member 5 includes the inter-core interposition part 56. , Placement workability can be improved. Further, since the inter-core interposition part 56 can be used for a gap between the inner core part 31 and the outer core part 32, even when a gap is required, the gap material can be reduced or omitted. Further, when the resin part 100 is provided as in the second embodiment to be described later, a space provided between the inner core part 31 and the outer core part 32 by the inter-core interposition part 56 is filled with the constituent resin of the resin part 100.
  • the filled resin can be used for the gap, and the resin portion 100 can be used as an adhesive for the core portions 31 and 32. Therefore, since the insulating member 5 includes the inter-core interposition part 56, the gap material arranging step and the joining step can be reduced or omitted, and the number of assembly steps can be reduced. In addition, since the constituent resin of the resin part 100 is filled between both the core parts 31 and 32, the bonding area between the resin part 100 in the assembly of the coil 2, the magnetic core 3, and the insulating member 5 increases. Therefore, the rigidity of the assembly by the resin part 100 can be improved to reduce noise.
  • the shape, size, and arrangement position of the inter-core interposition part 56 can be selected as appropriate. For example, only one protrusion or three or more protrusions constituting the inter-core interposition part may be provided for one coil element (for example, one protrusion from the central band part 52c in the insulating member 5 of the first embodiment). Protruding, etc.) Further, the smaller the area covering the end surface 31e of the inner core part 31 in the inter-core interposition part 56 (for example, the inter-core interposition part 56 is a rod-like protrusion), the resin is provided when the resin part 100 is provided.
  • the amount of resin filled between the inner core portion 31 and the outer core portion 32 can be further increased, in addition to being easy to fill the constituent resin of the portion 100 (it is difficult to inhibit the flow of the constituent resin and easy to deaerate),
  • the joint area with the resin part 100 can be further increased.
  • the amount of material used for the insulating member 5 can be reduced. Therefore, it is expected that the inter-core interposition part 56 is preferably provided so that the area covering the end surface 31e of one inner core part 31 in the inter-core interposition part 56 is about 1% or more and 10% or less.
  • the total area covered by two inter-core interposition portions 56 (for example, inter-core interposition portions 56a and 56c) with respect to the end surface 31e of one inner core portion 31 is about 5%.
  • the inter-core interposition part 56 can also be omitted.
  • the insulating member 5 includes a positioning portion 58 for positioning the outer core portion 32.
  • the positioning portion 58 is a protrusion protruding from the core surface of the end surface interposed portion 52.
  • two projections are provided so as to sandwich two opposing surfaces of the rectangular parallelepiped outer core portion 32, and these two projections are used as positioning portions 58.
  • the shape, size, and arrangement position of the positioning portion 58 can be selected as appropriate. For example, only one protrusion may be provided, or a groove into which the outer core portion 58 is fitted may be used instead of the protrusion. Since the insulating member 5 includes the positioning portion 58, the outer core portion 32 can be easily positioned with respect to the insulating member 5, and the assembly workability is excellent.
  • the positioning part 58 can be omitted.
  • the insulating member 5 can have a notch (not shown) or a through hole (not shown) at an appropriate location.
  • notches and through-holes can be used as resin flow paths and degassing passages of the resin part 100 to improve filling workability. it can.
  • the amount of material used for the insulating member 5 can be reduced.
  • the central belt portion 52c is not a uniform flat surface, but a cross-sectional trapezoidal shape having an inclined surface with a high central portion in the width direction of the central belt portion 52c (a horizontal direction of the coil elements 2a and 2b) and a low edge portion.
  • the peripheral edge of the central belt portion 52c is cut out so as to have the inclined surface. Even if the end surface intervening portion 52 exists, the inclined surface makes it easy for the constituent resin to enter inside the coil elements 2a and 2b, and gas easily escapes to the outside.
  • a cutout or a through hole may be provided in the lower belt portion 52d or the inner interposition portion 54.
  • the bonding area between the coil 2 and the inner core parts 31, 31 and the resin part 100 can be increased and firmly fixed, and the coil 2 and the magnetic core 3 can be firmly fixed.
  • the rigidity of the combined body 10 can be increased.
  • the shape and number of notches and through-holes can be selected as appropriate.
  • the larger the number of notches and through-holes and the greater the number the more excellent the workability of filling the above-mentioned constituent resins, and it is possible to increase the bonding area of the resin part 100 and further reduce the amount of material used for the insulating member 5.
  • the notch or the through hole is provided when the coil surface of the end surface interposition part 52 is large or the protrusion length of the inner interposition part 54 is long, the above-described effect can be easily obtained.
  • the insulating member 5 includes a strip-shaped partition portion 59 protruding from the coil surface at the end surface interposed portion 52.
  • the partition portion 59 is interposed between the coil elements 2a and 2b when the insulating member 5 is assembled to the coil 2, and improves the insulation between the coil elements 2a and 2b.
  • the partitioning portion 59 functions as a guide at the time of assembly, so that the arrangement workability can be improved.
  • the protruding length of the partition part 59 (the length protruding from the coil surface) can be selected as appropriate.
  • the projecting length of the partition part 59 is substantially equal to the projecting length of the inner interposition part 54, but it can also be made longer, for example.
  • the intervening length of the partition portion 59 (the length along the central axis of the central band portion 52c) can also be selected as appropriate.
  • the partition part 59 is provided over the full length of the center belt
  • the partition part 59 can also be omitted.
  • Both the coil 2 and the magnetic core 3 can be of a known shape and material.
  • the winding 2w constituting the coil 2 has a coated wire having an insulation coating made of an insulating material (typically an enamel material such as polyamideimide) on the outer circumference of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof. It can be suitably used.
  • the conductor may have various shapes such as a rectangular wire having a rectangular cross-sectional shape, a round wire having a circular shape, and a deformed wire having a polygonal shape.
  • the coil 2 is an edgewise coil formed by edgewise winding a coated rectangular wire whose conductor is made of a copper rectangular wire and whose insulating coating is made of enamel.
  • the edgewise coil is easy to make a small coil by increasing the space factor, and contributes to the miniaturization of the reactor 1.
  • the coil elements 2a and 2b can be formed by separate windings 2w and joined by a connecting member (not shown) to form one coil 2, the coil element can be formed by one continuous winding 2w.
  • the end face shape of the coil 2 can be appropriately selected.
  • the end face shape is a shape configured by combining a straight line and a circular arc, at least a part of the outer peripheral surface of the coil 2 (coil elements 2a, 2b) is a flat surface.
  • advantages such as an improvement in heat dissipation due to an increase in contact area, and an improvement in stability during installation.
  • Examples of such end face shapes include a rectangular shape with rounded corners and a race track shape.
  • the end surface shape may be a shape substantially consisting of only a curve, typically a circle or an ellipse.
  • the region on each end side is drawn (stretched) from the turn portion in an appropriate direction, and typically a terminal member (not shown) is connected. Electric power is supplied to the coil 2 through the terminal member and the like.
  • the terminal member is also made of a conductive material such as copper, aluminum, or an alloy thereof.
  • the magnetic core 3 is typically made of a soft magnetic material such as iron, an iron alloy, a metal such as an alloy containing a rare earth element, or a non-metal such as ferrite.
  • the magnetic core 3 is formed by bonding a plurality of core pieces (in this example, a total of four of the two inner core portions 31 and 31 and the two outer core portions 32 and 32) with an adhesive or an adhesive tape. It can.
  • an adhesive may be filled in the space provided between the end surface 31e of the inner core portion 31 and the inner end surface 32e of the outer core portion 32 by the interposition of the insulating member 5.
  • segmentation number of a core piece can be selected suitably.
  • the number of divisions is smaller, the number of parts is smaller, and the number of assembly steps and the number of joining steps using an adhesive between core pieces can be reduced.
  • the core pieces are not joined to each other and the joining step can be omitted, by firmly fixing the core pieces together with an adhesive or the like, the rigidity of the magnetic core 3 is increased, and a noise reduction effect can be expected.
  • each core piece a green compact, a composite material including magnetic powder and resin, a laminated body in which a plurality of electromagnetic steel plates are laminated, and the like can be used.
  • a core piece using an electromagnetic steel sheet generally has a high saturation magnetic flux density.
  • the green compact is typically produced by subjecting a raw material powder to pressure treatment and then appropriate heat treatment.
  • the raw material powder is a soft magnetic powder composed of the above-mentioned soft magnetic material, and a coating powder comprising an insulating coating composed of silicone resin, phosphate, etc.
  • the above-mentioned soft magnetic material is a metal, soft magnetic powder
  • a mixed powder in which a resin such as a thermoplastic resin or an additive such as a higher fatty acid (typically, one that disappears or changes into an insulating material by heat treatment) is appropriately mixed with the coating powder.
  • a resin such as a thermoplastic resin or an additive such as a higher fatty acid (typically, one that disappears or changes into an insulating material by heat treatment)
  • the coating powder is used, an insulating material is interposed between the metal particles, and an insulating property is excellent, and a compacted product with low loss can be obtained.
  • the powder compact is made of pure iron powder (preferably coating powder) as the raw material powder, it is excellent in moldability and easy to produce a core piece.
  • the magnetic properties of the green compact include a saturation magnetic flux density of 1.0 T or more, further 1.6 T or more, 1.8 T or more, 2 T or more, and a relative magnetic permeability of 50 or more and 500
  • the composite material can be typically produced by injection molding, transfer molding, MIM (Metal Injection Molding), cast molding, press molding using magnetic powder and powdered solid resin, or the like.
  • MIM Metal Injection Molding
  • a composite material having a desired three-dimensional shape can be easily obtained by filling a molding die with a mixture of magnetic powder and resin and then curing the resin as appropriate. can get.
  • the magnetic powder a powder made of the soft magnetic material described above can be used. Only a single material powder or a combination of a plurality of types of powders of different materials may be used.
  • the magnetic powder in the composite material is not substantially plastically deformed as described above, and therefore is substantially the same as the magnetic powder used for the raw material.
  • the shape, size, and material of the magnetic powder of the raw material Is substantially maintained. Accordingly, when the average particle size of the magnetic powder is 1 ⁇ m or more and 1000 ⁇ m or less, particularly about 10 ⁇ m or more and 500 ⁇ m or less, the fluidity of the mixture is excellent, and the core piece can be easily manufactured using injection molding or the like.
  • the saturation magnetic flux density is high, and it is easy to obtain a low-loss core piece and a magnetic core, and thus a low-loss reactor.
  • the resin used as the binder in the composite material typically includes a thermosetting resin such as an epoxy resin, a phenol resin, a silicone resin, or a urethane resin.
  • thermoplastic resins such as PPS resin, polyimide resin, fluorine resin, and polyamide resin, room temperature curable resin, or low temperature curable resin can be used.
  • a composite material containing powder (filler) made of a non-magnetic material such as ceramics such as alumina and silica can be used.
  • This composite material can improve heat dissipation and suppress uneven distribution (uniform dispersion) of the magnetic powder.
  • the filler is finer than the magnetic powder, the decrease in the ratio of the magnetic powder due to the inclusion of the filler can be suppressed.
  • the content of the filler is 0.2% by mass or more and 20% by mass or less when the composite material is 100% by mass, the above effect can be sufficiently obtained.
  • the content of the magnetic powder in the composite material may be 20 volume% or more and 75 volume% or less when the composite material is 100%.
  • the content of the magnetic powder is 30% by volume or more, further 40% by volume or more.
  • the content of the magnetic substance powder is 70% by volume or less, further 65% by volume or less, and 60% by volume or less.
  • the above composite material can easily adjust the magnetic properties of the core piece by adjusting the material and content of the magnetic powder, the presence or absence of filler, and the like. That is, it is easy to manufacture a core piece or a magnetic core 3 having desired magnetic characteristics. Further, since the composite material contains a resin, even when the material of the magnetic powder is the same as the material of the particles constituting the green compact, the saturation magnetic flux density tends to be low and the relative permeability tends to be low. It is in. Examples of the magnetic properties of the composite material include a saturation magnetic flux density of 0.6 T or more, further 1.0 T or more, and a relative permeability of 5 or more and 50 or more, preferably 10 or more and 35 or less.
  • 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 made of a composite material composed of the same material as each core piece.
  • a BH curve tracer “BHS-40S10K” manufactured by Riken Denshi Co., Ltd. can be used.
  • the maximum value of the gradient (B / H) of the obtained BH initial magnetization curve is obtained, and this maximum value is set as the relative permeability of the core piece.
  • the magnetization curve here is a so-called DC magnetization curve.
  • the relative permeability here is a so-called DC permeability, which is different from the AC relative permeability measured in an AC magnetic field.
  • the saturation magnetic flux density of the core piece is defined as the magnetic flux density when a magnetic field of 10000 (Oe) is applied to the test piece with an electromagnet and sufficiently magnetically saturated.
  • the magnetic core 3 can be configured to have uniform magnetic characteristics as a whole, or partially different in magnetic characteristics.
  • a form in which the magnetic core 3 as a whole has uniform magnetic properties is typically exemplified by using all the core pieces constituting the magnetic core 3 manufactured by the same material and the same manufacturing method.
  • the inner core portion 31 and the outer core portion 32 are both compacted bodies, (2)
  • the inner core portion 31 and the outer core portion 32 are both composite materials. Etc.
  • the magnetic core 3 is partially different in magnetic properties from, for example, some core pieces as a green compact and other core pieces as composite materials, or all core pieces as composite materials.
  • the content and material of the magnetic powder of the core piece of the part may be made different, or the material of the inner core part 31 and the material of the outer core part 32 may be made different.
  • (3) The inner core portion 31 is a green compact, and the outer core portion 32 is a composite material.
  • the inner core portion 31 is a composite material, and the outer core portion 32 is a green compact.
  • the inner core portion 31 and the outer core portion 32 are both composite materials, and the materials of the composite materials are different.
  • Both the inner core part 31 and the outer core part 32 are formed into a green compact, and the materials are different. Etc.
  • the magnetic core 3 can include a gap material (not shown) made of a material having a relative permeability lower than that of the core piece.
  • the gap material is not separately provided, and if the gap is constructed by the inter-core interposition part 56 of the insulating member 5, the number of parts is small, and the gap material arranging process and fixing process can be omitted. Excellent workability. If the relative magnetic permeability of at least one of the core pieces constituting the magnetic core 3 is lower than that of the other core pieces, magnetic saturation is unlikely to occur and the gap is easily omitted.
  • the material of the magnetic core 3 is adjusted so that the relative magnetic permeability of the entire magnetic core 3 is 5 or more and 100 or less, and further 10 or more and 50 or less, a gapless structure can be obtained.
  • both the inner core portions 31 and 31 are made of the same composite material, and the outer core portions 32 and 32 are both made of the same material compacted body, as described above.
  • a gap (mainly an air gap) is provided between the core portion 31 and the outer core portion 32.
  • the surface on the installation side of the outer core portions 32, 32 (lower surface in FIGS. 1 to 3) is from the surface on the installation side of the inner core portions 31, 31 (lower surface in FIGS. 1 to 3). And is flush with the surface on the coil 2 installation side (the lower surface in FIGS. 1 to 3).
  • the reactor 1 is excellent in stability, has an increased contact area with the installation target, and is excellent in heat dissipation.
  • the case may be configured to include a case (not shown) for housing the combined body 10 of the coil 2 and the magnetic core 3.
  • the case includes a bottom portion and a wall portion erected from the bottom portion, and various shapes and sizes of containers having an opening on the side facing the bottom portion can be used.
  • the constituent material of the case includes a nonmagnetic metal material, specifically, aluminum or an alloy thereof, magnesium or an alloy thereof. Since these metals have electrical conductivity, high strength, and high thermal conductivity, cases made of these metals have a magnetic shield that suppresses magnetic flux leakage to the outside of the case and the external environment (dust dust). And mechanical protection and heat dissipation path.
  • the bottom part is a plate made of the above metal
  • the wall part is made of an insulating material such as a resin, and when these assembled cases are used, the insulation between the coil and the wall is improved, the weight is reduced, and the combination 10 It is possible to expect effects such as improvement in storage workability (a case where a case is assembled by attaching a wall portion after arranging the combined body 10 on a plate material).
  • It can be configured to include a lid (not shown) so as to cover the opening of the case.
  • a lid (not shown) so as to cover the opening of the case.
  • (1) prevention of falling off of the stored item in the case (2) protection of the stored item, in particular, when the cover part is made of the above-mentioned nonmagnetic metal material, the above (1),
  • effects such as (3) prevention of magnetic flux leakage and (4) improvement of heat dissipation by using for heat dissipation path can be expected.
  • a fastening member such as a bolt or an adhesive can be used for fixing the lid.
  • thermo radiation sheet (not shown) between the assembly 10 and the installation object or the inner bottom surface of the case.
  • a material composed of a material having excellent thermal conductivity and excellent insulating properties for example, a resin containing a filler made of ceramics (such as an epoxy resin) can be suitably used.
  • This form can improve heat dissipation.
  • a heat dissipation sheet made of a relatively soft material for example, silicone resin
  • an effect of reducing noise can be expected.
  • (Use) Reactor 1 having the above-described configuration is, for example, an application in which energization conditions are, for example, a maximum current (DC) of 100A to 1000A, an average voltage of 100V to 1000V, and a use frequency of 5kHz to 100kHz. Specifically, it can be suitably used as a component part of an in-vehicle power conversion device such as an electric vehicle or a hybrid vehicle.
  • DC maximum current
  • Reactor manufacturing method Reactor 1 is assembled as follows. As shown in FIG. 3, inner core portions 31, 31 and outer core portions 32, 32, and insulating members 5A, 5B for constructing the coil 2 and the magnetic core 3 are prepared. Then, the inner core portions 31 and 31 are inserted into the coil elements 2a and 2b, respectively. One insulating member 5A is arranged so as to cover one end face of both coil elements 2a, 2b and a part of one end face 31e, 31e of both inner core portions 31, 31 (see also FIG. 2 (C)).
  • the other insulating member 5B is disposed so as to cover the other end surfaces of both coil elements 2a, 2b and the other end surfaces 31e, 31e of both inner core portions 31, 31 (see also FIG. 2 (C)).
  • the inner interposed portions 54a and 54b of the insulating members 5A and 5B also function as guides.
  • one outer core portion 32 is brought into contact with the core surface of the end surface interposed portion 52 of one insulating member 5A, and the other outer core portion 32 is brought into contact with the core surface of the end surface interposed portion 52 of the other insulating member 5B.
  • the coil 2 and the inner core portions 31, 31 are assembled so as to be sandwiched between the outer core portions 32, 32.
  • the positioning portion 58 of the insulating members 5A and 5B also functions as a guide.
  • the inner end surfaces 32e, 32e of the outer core portions 32, 32 are respectively arranged so as to cover the end surfaces 31e, 31e of the inner core portions 31, 31 arranged side by side, thereby forming the annular magnetic core 3.
  • reactor 1 is built.
  • the reactor 1 has a small number of parts by using the insulating member 5 formed integrally with a portion disposed inside the cylindrical coil 2 and a portion disposed on the end face of the coil 2, There are few assembly processes. Further, the reactor 1 can perform the positioning of the insulating member 5 with respect to the coil 2 and the inner core portion 31 and the positioning of the insulating member 5 with respect to the end surface of the coil 2 by fitting the insulating member 5 into the coil 2. Therefore, the reactor 1 is excellent in assembling workability and can improve productivity.
  • the reactor 1 shown in this example is superior in assembling workability and can further improve productivity from the following points.
  • the inter-core interposition part 56 By providing the inter-core interposition part 56, the inner core part 31 and the outer core part 32 can be easily positioned at a predetermined interval, and the inter-core interposition part 56 serves as a stopper to insulate It is easy to arrange the member 5 in the assembly of the coil 2 and the inner core portions 31 and 31.
  • the predetermined interval can be used for the gap by the inter-core interposition part 56, and the reactor 1 does not need to be provided with a gap material even though it has the gap.
  • the positioning portion 58 By providing the positioning portion 58, the outer core portion 32 can be easily positioned with respect to the insulating member 5.
  • the coil surface of the end surface interposition part 52 is the above-described inclined surface, and the insulating member 5 is easily positioned and placed in close contact with the coil 2 and is easily disposed.
  • the coil surface of the end surface interposed portion 52 is sufficiently large, and the coil 2 can be sufficiently pressed when the insulating member 5 is assembled to the coil 2.
  • the partition portion 59 can be used as a guide, and the insulating member 5 can be easily disposed on the coil 2.
  • the number of core pieces constituting the magnetic core 3 is small (four in this case), and the core pieces constituting the inner core portions 31 and 31 and the outer core portions 32 and 32 are all integrated and assembled. The number of processes is small.
  • the insulating member 5 provided in the reactor 1 is disposed only on a part of the annular end surface of the coil 2 and has a shape disposed only on a part of the cylindrical inner peripheral surface of the coil 2. The amount of material used can also be reduced.
  • any form of the insulating member can increase the number of portions (exposed portions) where the coil 2 is not covered. Therefore, in the case where the resin part 100 is provided as in Embodiment 2 described later, these forms improve the workability of filling the resin of the resin part 100, increase the contact area with the resin part 100, Noise can be reduced by improving the rigidity, and the amount of material used for the insulating member can be reduced.
  • the configuration in which the insulating member 5A is disposed on one end surface side of the coil elements 2a and 2b and the insulating member 5B is disposed on the other end surface side of the coil elements 2a and 2b has been described.
  • the element 2a may be disposed only on one end surface side
  • the other insulating member may be disposed only on the other end surface side of the other coil element 2b.
  • the insulating member 5A (or 5B) in the first embodiment is cut along the central axis of the central band portion 52c, and the insulating member has a shape having only a portion that can be placed on one coil element (so-called half-sink). A cracked insulating member) can be used.
  • One coil element 2a, one inner core portion 31, and one outer core portion 32 can be positioned by an insulating member (half-cracked) disposed on one end surface side of one coil element 2a.
  • the other coil element 2b, the other inner core part 31, and the other outer core part 32 can be positioned by another (half-cracked) insulating member disposed on the other end face side of the other coil element 2b.
  • This configuration can further increase the number of locations (exposed locations) where the coil 2 is not covered by the insulating member 5. Therefore, in the case where the resin portion 100 is provided as in Embodiment 2 described later, this form further improves the filling workability of the resin of the resin portion 100, further increases the contact area with the resin portion 100, Noise can be further reduced by improving the rigidity of the integral object, and the amount of material used for the insulating member can be further reduced.
  • Examples of the reactor of the second embodiment include a form including a resin portion 100 (FIG. 1) that covers the combined body 10 of the coil 2 and the magnetic core 3 that are main constituent members of the reactor 1 of the first embodiment.
  • the form including the resin part 100 includes a case (not shown) for housing the union 10 and a form or case including the resin part 100 filled in the case and sealing the union 10.
  • a form (caseless form) including the resin part 100 that does not have and covers the outer periphery of the combined body 10 and forms the outer peripheral surface of the reactor is included.
  • the form with the resin part 100 is protection of the assembly 10 from the external environment (improvement of corrosion resistance, protection from dust, etc.), protection of mechanical strength, improvement of heat dissipation depending on the material and thickness, suppression of vibration It is possible to reduce or suppress noise caused by noise.
  • the notched and opened portion of the insulating member 5 is discharged from the resin flow path of the constituent resin of the resin part 100, between the coil 2 and the inner core part 31, and the like. It can be used as a deaeration passage. Therefore, in this embodiment, the constituent resin of the resin portion 100 can be filled with accuracy and in a short time.
  • examples of the constituent resin of the resin portion 100 include an insulating resin such as an epoxy resin, a urethane resin, and a silicone resin.
  • the constituent resin preferably has a heat conductivity of 0.5 W / m ⁇ K or more, and more preferably 1.0 W / m ⁇ K or more because of excellent heat dissipation. If a resin containing a filler with excellent insulation and heat dissipation (preferably with a thermal conductivity of 2.0 W / mK or more) is used as the constituent resin of the resin part 100, the coil 2 or magnetic core 3 and the case The insulation and heat dissipation can be further improved.
  • the material of the filler examples include ceramics such as at least one selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide.
  • the resin part 100 is a resin having a high adhesive force, the coil 2, the magnetic core 3 and the insulating member 5 can be firmly fixed, and a noise reduction effect can be expected by improving the rigidity of these assemblies.
  • the resin part 100 is made of a resin having a certain degree of hardness (such as an epoxy resin), noise can be effectively reduced.
  • the constituent resin of the resin part 100 is preferably an insulating resin.
  • the resin is capable of transfer molding or injection molding, the shape along the outer shape of the combined body 10 can be molded well.
  • the resin include thermosetting resins such as epoxy resin, silicone resin, and unsaturated polyester, and thermoplastic resins such as PPS resin and LCP.
  • the resin part 100 preferably has a thermal conductivity of 0.5 W / m ⁇ K or more, more preferably 1.0 W / m ⁇ K or more. Resin containing the above-mentioned filler can also be utilized.
  • the coil 2 may include only one coil element.
  • the magnetic core includes one having a columnar inner core portion disposed in the coil element and an outer core portion disposed so as to connect both end faces of the inner core portion.
  • the inner core portion can also be constructed by combining a plurality of core pieces, but it is preferable that the number of parts is reduced and the number of assembly steps can be reduced if it is a single body (one core piece) as in the first embodiment. . If the outer core part is also a single body (one core piece), the number of parts can be reduced.
  • the outer core portion may be formed in a square shape.
  • the outer core portion can be constructed by combining a plurality of core pieces.
  • the outer core portion includes a bottomed cylindrical core piece and a plate-like core piece that connects one end surface of the cylindrical core piece and one end surface of the inner core portion, The form which provides two core pieces and the said plate-shaped core piece is mentioned. In these forms, the outer core portion can be easily assembled to the outer periphery of the coil, and the assembly workability is excellent.
  • the insulating member may be, for example, a half-cracked insulating member described in Modification 3 above.
  • This form is also excellent in productivity by including the insulating member including the end surface interposition part and the inner interposition part as described above. Further, the amount of material used for the constituent parts (insulating members) of the reactor can be reduced. Note that this form can also be a form including the resin portion described in the second embodiment. In this case, as described above, there are effects that the resin portion is excellent in filling workability of the constituent resin, the contact area with the resin portion can be increased, and the rigidity of the integral object can be increased to reduce noise.
  • Embodiment 4 The reactors of Embodiments 1 to 3 and the reactors of Modifications 1 to 3 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 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. 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.
  • an inlet is shown as a charging point of the vehicle 1200, but a form including a plug may be adopted.
  • the power converter 1100 includes a converter 1110 that is connected to the main battery 1210 and converts an input voltage, and an inverter 1120 that is connected to the converter 1110 and performs 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 travels, and feeds the converted electric power to the motor 1220 to drive the motor 1220. During regeneration, the alternating current from the motor 1220 The output is converted to direct current and output to converter 1110.
  • 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 to third embodiments and the reactors of the first to third modifications.
  • 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 reactor of the power supply device converter 1150 and the auxiliary power supply converter 1160 has the same configuration as the reactors of the first to third embodiments and the reactors of the first to third modifications, and the reactor is appropriately changed in size and shape. Can be used.
  • the reactors of the first to third embodiments and the reactors of the first to third modifications may be used for a converter that performs input power conversion and that only performs step-up or a step-down converter.
  • the reactor of the present invention can be used for components of power conversion devices such as DC-DC converters and air conditioner converters mounted on vehicles such as hybrid vehicles, plug-in hybrid vehicles, electric vehicles, and fuel cell vehicles.
  • power conversion devices such as DC-DC converters and air conditioner converters mounted on vehicles such as hybrid vehicles, plug-in hybrid vehicles, electric vehicles, and fuel cell vehicles.
  • Reactor 10 Combination 100 Resin part 2 Coil 2a, 2b Coil element 2r Coupling part 2w Winding 3 Magnetic core 31 Inner core part 31e End face 32 Outer core part 32e Inner end face 5, 5A, 5B Insulating member 52 End face interposition part 52c Center Belt part 52u Upper line part 52d Lower belt part 54,54a, 54b Inner interposition part 56,56a, 56b, 56c, 56d Inter-core interposition part 58 Positioning part 59 Partition part 1100 Power converter 1110 Converter 1111 Switching element 1112 Drive circuit L Reactor 1120 Inverter 1150 Power supply converter 1160 Auxiliary power converter 1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub-battery 1240 Auxiliary 1250 Wheel

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Dc-Dc Converters (AREA)
  • Insulating Of Coils (AREA)

Abstract

La présente invention se rapporte à un réacteur qui comprend : une bobine cylindrique (un élément de bobine) formée en enroulant un enroulement selon une forme hélicoïdale ; un noyau magnétique qui comporte une partie de noyau interne positionnée à l'intérieur de la bobine et une partie de noyau externe dans laquelle la bobine n'est pas positionnée ; et un élément isolant positionné entre la bobine et le noyau magnétique. L'élément isolant est formé en moulant intégralement une partie d'interposition de surface d'extrémité qui est intercalée entre la partie de noyau externe et l'une des surfaces d'extrémité annulaires de la bobine, et une partie d'interposition interne qui est intercalée au milieu afin de positionner la bobine et la partie de noyau interne. La partie d'interposition d'extrémité est positionnée le long de la surface d'extrémité annulaire de la bobine, seulement sur une partie de la surface dans la direction circonférentielle de cette dernière. La partie d'interposition interne est positionnée le long de la surface périphérique interne cylindrique de la bobine, seulement sur une partie de la surface dans la direction circonférentielle de cette dernière.
PCT/JP2014/050918 2013-01-25 2014-01-20 Réacteur, convertisseur et dispositif de conversion de puissance WO2014115672A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2013011688A JP5983942B2 (ja) 2013-01-25 2013-01-25 リアクトル、コンバータ、及び電力変換装置
JP2013-011688 2013-01-25

Publications (1)

Publication Number Publication Date
WO2014115672A1 true WO2014115672A1 (fr) 2014-07-31

Family

ID=51227463

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2014/050918 WO2014115672A1 (fr) 2013-01-25 2014-01-20 Réacteur, convertisseur et dispositif de conversion de puissance

Country Status (2)

Country Link
JP (1) JP5983942B2 (fr)
WO (1) WO2014115672A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017043523A1 (fr) * 2015-09-11 2017-03-16 株式会社オートネットワーク技術研究所 Bobine de réactance
JP2017139327A (ja) * 2016-02-03 2017-08-10 株式会社オートネットワーク技術研究所 リアクトル
CN107924754A (zh) * 2015-09-11 2018-04-17 株式会社自动网络技术研究所 电抗器
CN112789700A (zh) * 2018-10-29 2021-05-11 株式会社自动网络技术研究所 电抗器
CN113168960A (zh) * 2018-12-03 2021-07-23 株式会社自动网络技术研究所 电抗器

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6130349B2 (ja) * 2014-12-25 2017-05-17 トヨタ自動車株式会社 リアクトルの製造方法
JP6358565B2 (ja) * 2015-07-24 2018-07-18 株式会社オートネットワーク技術研究所 リアクトル、およびリアクトルの製造方法
JP6489029B2 (ja) * 2016-01-14 2019-03-27 株式会社オートネットワーク技術研究所 リアクトル
US11069471B2 (en) 2016-01-29 2021-07-20 Autonetworks Technologies, Ltd. Reactor
JP6547646B2 (ja) 2016-01-29 2019-07-24 株式会社オートネットワーク技術研究所 リアクトル、及びリアクトルの製造方法
JP6683957B2 (ja) * 2017-03-07 2020-04-22 株式会社オートネットワーク技術研究所 リアクトル
JP6508622B2 (ja) * 2018-06-14 2019-05-08 株式会社オートネットワーク技術研究所 リアクトル、およびリアクトルの製造方法
JP7124635B2 (ja) * 2018-10-25 2022-08-24 株式会社オートネットワーク技術研究所 リアクトル
JP2020141025A (ja) * 2019-02-27 2020-09-03 トヨタ自動車株式会社 リアクトル

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2011060915A (ja) * 2009-09-08 2011-03-24 Toyota Industries Corp リアクトル
JP2012070001A (ja) * 2011-12-20 2012-04-05 Sumitomo Electric Ind Ltd リアクトル及びリアクトル用ボビン

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4153368B2 (ja) * 2003-06-04 2008-09-24 株式会社タムラ製作所 リアクター
JP5400726B2 (ja) * 2010-08-02 2014-01-29 株式会社タムラ製作所 インダクタンスユニット

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2011060915A (ja) * 2009-09-08 2011-03-24 Toyota Industries Corp リアクトル
JP2012070001A (ja) * 2011-12-20 2012-04-05 Sumitomo Electric Ind Ltd リアクトル及びリアクトル用ボビン

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017043523A1 (fr) * 2015-09-11 2017-03-16 株式会社オートネットワーク技術研究所 Bobine de réactance
CN107924754A (zh) * 2015-09-11 2018-04-17 株式会社自动网络技术研究所 电抗器
CN107924754B (zh) * 2015-09-11 2020-03-10 株式会社自动网络技术研究所 电抗器
JP2017139327A (ja) * 2016-02-03 2017-08-10 株式会社オートネットワーク技術研究所 リアクトル
CN108604495A (zh) * 2016-02-03 2018-09-28 株式会社自动网络技术研究所 电抗器
US11017935B2 (en) 2016-02-03 2021-05-25 Autonetworks Technologies, Ltd. Reactor
CN112789700A (zh) * 2018-10-29 2021-05-11 株式会社自动网络技术研究所 电抗器
CN112789700B (zh) * 2018-10-29 2023-01-13 株式会社自动网络技术研究所 电抗器
CN113168960A (zh) * 2018-12-03 2021-07-23 株式会社自动网络技术研究所 电抗器
CN113168960B (zh) * 2018-12-03 2023-04-07 株式会社自动网络技术研究所 电抗器

Also Published As

Publication number Publication date
JP2014143332A (ja) 2014-08-07
JP5983942B2 (ja) 2016-09-06

Similar Documents

Publication Publication Date Title
JP5983942B2 (ja) リアクトル、コンバータ、及び電力変換装置
US9449745B2 (en) Reactor, reactor-use coil component, converter, and power converter apparatus
US9460842B2 (en) Reactor, coil mold product, converter, and power converter apparatus
JP6065609B2 (ja) リアクトル、コンバータ、及び電力変換装置
WO2013051421A1 (fr) Bobine de réactance, composant de bobine destiné à une bobine de réactance, convertisseur et dispositif de conversion électronique de puissance
WO2014103521A1 (fr) Réacteur, convertisseur et dispositif de conversion d'énergie
WO2013005573A1 (fr) Réactance, convertisseur et dispositif de conversion électrique
WO2012008328A1 (fr) Réacteur
JP6024886B2 (ja) リアクトル、コンバータ、及び電力変換装置
WO2013011780A1 (fr) Inductance, convertisseur et dispositif de conversion d'énergie
JP2013118352A (ja) リアクトル、リアクトル用コイル部品、コンバータ、及び電力変換装置
JP6032551B2 (ja) リアクトル、コンバータ、及び電力変換装置
JP6048652B2 (ja) リアクトル、コンバータ、および電力変換装置
JP2015012147A (ja) リアクトル
JP2013153025A (ja) リアクトル、コンバータ、及び電力変換装置
JP5945906B2 (ja) リアクトルの収納構造体、および電力変換装置
JP2013162069A (ja) リアクトル、コンバータ、及び電力変換装置
WO2013168538A1 (fr) Réacteur, convertisseur, dispositif de conversion d'énergie électrique et méthode de fabrication de pièce de noyau en résine
JP2013179186A (ja) リアクトル、リアクトル用部品、コンバータ、及び電力変換装置
WO2013118524A1 (fr) Réacteur, convertisseur, dispositif de conversion de puissance et matériau de noyau pour réacteur
JP2015050298A (ja) リアクトル、コンバータ、及び電力変換装置
JP6048821B2 (ja) リアクトル、コンバータ、及び電力変換装置
JP2013026418A (ja) リアクトル
JP2013179258A (ja) リアクトル、コンバータ及び電力変換装置、並びにリアクトル用コア部品
JP2014067759A (ja) リアクトル、コンバータ、及び電力変換装置

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 14743559

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 14743559

Country of ref document: EP

Kind code of ref document: A1