WO2015159673A1

WO2015159673A1 - Electronic device

Info

Publication number: WO2015159673A1
Application number: PCT/JP2015/059143
Authority: WO
Inventors: 辰哉上松
Original assignee: 株式会社豊田自動織機
Priority date: 2014-04-16
Filing date: 2015-03-25
Publication date: 2015-10-22
Also published as: TW201603062A; JP2015204448A; JP5835396B2

Abstract

This electronic device comprises an inductive device, a case, and a spacer. The inductive device comprises a core and a plurality of coils. The core has a plurality of legs around which the respective coils are wound. The case contains the inductive device and is filled with a resin. The spacer comprises a resin and is positioned in a gap between radially-adjacent coils.

Description

Electronics

According to the present invention, an induction device such as a reactor or a transformer having a core having a plurality of legs and a plurality of coils wound respectively on the legs and an induction device housed inside and filled with a resin The present invention relates to an electronic device provided with a case.

For example, the electronic device described in Patent Document 1 includes a core having a plurality of legs, and a plurality of induction devices such as a reactor and a transformer each having a plurality of coils wound around each leg, and a metal for housing the induction device It is equipped with a case made of The induction device is fixed to the case by a resin (potting resin) filled in the case. And while insulation with each coil and a case is ensured by resin, the heat from induction apparatus is thermally radiated to a case through resin, and the temperature rise of an induction apparatus is suppressed.

JP 2007-243131 A

When the coils wound around the legs are adjacent to each other in the radial direction of the coil, a gap is formed between the adjacent coils. Since the resin filled in the case flows into the gap between the coils, the larger the gap, the larger the amount of resin flowing into the gap, and the larger the amount of resin filled in the case.

An object of the present invention is to provide an electronic device capable of reducing the amount of resin filled in a case.

An electronic device to solve the above problems includes: a core having a plurality of legs; and an induction device having a plurality of coils wound around the legs, a case for accommodating the induction device, and filling the case And a resin spacer disposed in a gap between the coils adjacent to each other in the radial direction.

The disassembled perspective view which shows the reactor apparatus in 1st Embodiment. The longitudinal cross-sectional view of the induction instrument of FIG. FIG. 3 is an exploded perspective view of the induction device of FIG. 2; FIG. 2 is a cross-sectional plan view of the induction device of FIG. 1; The longitudinal cross-sectional view of the electronic device containing the induction apparatus of FIG. The disassembled perspective view of the guidance apparatus in 2nd Embodiment. The disassembled perspective view of the guidance instrument in 3rd Embodiment. The disassembled perspective view of the guidance instrument in 4th Embodiment.

Hereinafter, a first embodiment of a reactor device 10, which is a type of electronic device, will be described with reference to FIGS.
As shown in FIG. 1, the reactor device 10 includes an induction device 11 and a case 12 for housing the induction device 11. The induction device 11 has two cores, ie, a first core 21 and a second core 22, and two coils, ie, a first coil 31 and a second coil 32. The case 12 has a bottomed elliptical cylindrical shape and is made of metal (made of aluminum in the present embodiment). The induction device 11 is housed in the case 12 such that the first core 21 is located between the second core 22 and the bottom of the case 12.

As shown in FIGS. 2 and 3, the first core 21 and the second core 22 are U-shaped cores. The first core 21 and the second core 22 are magnetic members and are formed of dust cores.
The first core 21 includes a flat plate portion 21 a having a substantially rectangular flat plate shape and a plurality of leg portions. The plurality of leg portions extend from the other end of the flat plate portion 21 a toward the second core 22 from a cylindrical first leg portion 21 b extending toward the second core 22 from one end in the longitudinal direction of the flat plate portion 21 a. And an extending cylindrical second leg 21c.

The first core 21 has first side surfaces 21 d located at both ends in the longitudinal direction of the flat plate portion 21 a and second side surfaces 21 f located at both ends in the lateral direction of the flat portion 21 a. The pair of second side surfaces 21 f extend in parallel to each other along the longitudinal direction of the flat plate portion 21 a. Each first side surface 21d is connected to the pair of second side surfaces 21f, and bulges out gradually from the pair of second side surfaces 21f in the longitudinal direction of the flat plate portion 21a.

The second core 22 includes a flat plate portion 22 a having a substantially rectangular flat plate shape and a plurality of leg portions. The plurality of leg portions extend from the other end of the flat plate portion 22 a toward the first core 21 from the other end in the longitudinal direction of the flat plate portion 22 a, and toward the first core 21. And an extending cylindrical second leg 22c.

The second core 22 has first side surfaces 22d located at both ends in the longitudinal direction of the flat plate portion 22a and second side surfaces 22f located at both ends in the lateral direction of the flat portion 22a. The pair of second side surfaces 22f extend in parallel to each other along the longitudinal direction of the flat plate portion 22a. Each first side face 22d is connected to the pair of second side faces 22f and bulges away from the pair of second side faces 22f in the longitudinal direction of the flat plate portion 22a.

The first core 21 has the same shape as the second core 22. Further, in the first and

second cores

21 and 22, the end faces in the extending direction of the

first legs

21b and 22b face each other, and the end faces in the extending direction of the

second legs

21c and 22c face each other It is arranged to be.

A gap plate 13 is interposed between the end surfaces of the

first legs

21b and 22b and between the end surfaces of the

second legs

21c and 22c. Each gap plate 13 is a nonmagnetic material (for example, ceramic), and is formed in a disk shape having the same outer diameter as the

first legs

21b and 22b and the

second legs

21c and 22c. The gap plate 13 forms a gap between the end faces of the

first legs

21b and 22b and between the end faces of the

second legs

21c and 22c.

As shown in FIGS. 2 and 3, a first bobbin 41 as a bobbin is attached to the first core 21, and a second bobbin 42 as a bobbin is attached to the second core 22. The first bobbin 41 and the second bobbin 42 are made of resin. In the present embodiment, the first bobbin 41 and the second bobbin 42 are formed of polyphenylene sulfide resin (PPS resin).

The first bobbin 41 has a flat plate portion 41a, a cylindrical first cylindrical portion 41b projecting from the flat plate portion 41a, and a cylindrical second cylindrical portion 41c projecting from the flat plate portion 41a. The first leg portion 21b of the first core 21 is inserted into the first cylindrical portion 41b, and the second leg portion 21c of the first core 21 is inserted into the second cylindrical portion 41c.

The second bobbin 42 has a flat plate portion 42a, a cylindrical first cylindrical portion 42b projecting from the flat plate portion 42a, and a cylindrical second cylindrical portion 42c projecting from the flat plate portion 42a. The first leg 22b of the second core 22 is inserted into the first tubular portion 42b, and the second leg 22c of the second core 22 is inserted into the second tubular portion.

In the first and

second bobbins

41 and 42, the tips in the projecting direction of the first

cylindrical portions

41b and 42b face each other, and the tips in the projecting direction of the second

cylindrical portions

41c and 42c face each other Is located in The flat plate portion 41 a of the first bobbin 41 has the same outer shape as the flat plate portion 42 a of the second bobbin 42.

The first coil 31 has an annular shape, and is wound around the first

cylindrical portions

41b and 42b into which the

first legs

21b and 22b are inserted. The second coil 32 has an annular shape, and is wound around the second

cylindrical portions

41c and 42c into which the

second legs

21c and 22c are inserted. In the present embodiment, the first and

second coils

31 and 32 are formed by edgewise bending a single conductive plate, and the tip of the first coil 31 is the tip of the second coil 32 and the connecting portion 33. Are linked at The first coil 31 wound on the

first legs

21b and 22b (that is, the first

cylindrical portions

41b and 42b), and the

second legs

21c and 22c (that is, the second

cylindrical portions

41c and 42c) The second coil 32 and the coiled second coil 32 are disposed radially adjacent to each other, and a connecting portion 33 is provided in a gap between the

coils

31 and 32. The winding direction of the first coil 31 is different from the winding direction of the second coil 32. The first and

second coils

31 and 32 may be integrally formed by edgewise bending a single conductive plate.

As shown in FIGS. 3 and 4, the pair of spacers 51 having a substantially trapezoidal shape in plan view are integrated with the first bobbin 41 so that they project from the flat plate portion 41 a of the first bobbin 41 in the thickness direction of the flat plate portion 41 a. Are formed. Each spacer 51 is disposed in a gap between the first coil 31 and the second coil 32. The spacer 51 is made of resin. In the present embodiment, the spacer 51 is formed of polyphenylene sulfide resin (PPS resin) which is the same material as the first and

second bobbins

41 and 42.

Each spacer 51 extends from the side edge extending in the longitudinal direction of the flat plate portion 41a in a direction perpendicular to the upper surface of the flat plate portion 41a, that is, the lower bottom portion 51a extending in the thickness direction of the flat plate portion 41a And an upper bottom portion 51b extending in the thickness direction of the flat plate portion 41a. Each spacer 51 has a pair of curved portions 51c extending so as to curve in an arc from both side edges of the lower bottom portion 51a in the longitudinal direction to both side edges of the upper bottom portion 51b in the longitudinal direction. The curved portion 51 c extends along the outer peripheral surfaces of the first coil 31 and the second coil 32, and contacts the outer peripheral surfaces of the first coil 31 and the second coil 32. Furthermore, each spacer 51 has an extending portion 51 d which is continuous with the lower bottom portion 51 a, the upper bottom portion 51 b and the pair of curved portions 51 c and extends along the flat plate portion 42 a of the second bobbin 42. Each extending portion 51 d contacts the flat plate portion 42 a of the second bobbin 42. The upper bottom portions 51b of the spacer 51 are disposed to face each other, and a space 33k in which the connecting portion 33 is disposed is formed between the upper bottom portions 51b.

As shown in FIG. 1, the case 12 has an inner circumferential surface 12 a formed along the outer shape of the induction device 11. Specifically, the inner circumferential surface 12 a of the case 12 is formed along the outer shape of the

flat plate portions

41 a and 42 a of the first and

second bobbins

41 and 42.

As shown in FIG. 5, a part of the induction device 11 is covered by a resin 29 filled in the case 12. The resin 29 is made of a resin (for example, epoxy resin) different from the first bobbin 41 and the second bobbin 42. The resin 29 ensures insulation between the

coils

31 and 32 and the case 12. The induction device 11 is thermally coupled to the case 12 via the resin 29. Then, the heat from the induction device 11 is dissipated to the case 12 through the resin 29.

Next, the operation of the present embodiment will be described.
The first coil 31 wound around the

first legs

21 b and 22 b and the second coil 32 wound around the

second legs

21 c and 22 c are disposed adjacent to each other in the radial direction. Each spacer 51 is disposed in a gap between the first coil 31 and the second coil 32. Therefore, it is not necessary to fill the gap between the adjacent first and

second coils

31 and 32 with the resin 29 filled in the case 12. As a result, the amount of the resin 29 filled in the case 12 is smaller than in the case where the spacer 51 is not present in the gap between the adjacent first and

second coils

31 and 32.

A part of the first coil 31 and a part of the second coil 32 are in contact with the pair of spacers 51, that is, each spacer 51 is in contact with a part of the

coils

31 and 32 adjacent to the spacer 51. Therefore, the heat generated from the first and

second coils

31 and 32 is transmitted to the first core 21 through the spacers 51. Then, the heat transmitted to the first core 21 is dissipated to the case 12, whereby the temperature rise of the induction device 11 is suppressed.

The following effects can be obtained in the above embodiment.
(1) The spacer 51 is disposed in the gap between the first coil 31 and the second coil 32. According to this, when the resin 29 is filled in the case 12, it is not necessary to fill the gap between the adjacent first and

second coils

31 and 32 with the resin 29. Therefore, the amount of the resin 29 filled in the case 12 can be reduced as compared with the case where the spacer 51 is not present in the gap between the adjacent first and

second coils

31 and 32. Since the material cost of the resin 29 is high with respect to the material cost of the spacer 51, the material cost can be suppressed by reducing the weight of the resin 29. Further, since the time until the resin 29 is filled in the gap can be reduced, the manufacturing cost can be suppressed.

(2) Each spacer 51 is integrally formed on the first bobbin 41. According to this, when the first bobbin 41 is molded, the respective spacers 51 can be molded simultaneously with the first bobbin 41, so that the reactor device 10 can be easily manufactured.

(3) The inner circumferential surface 12 a of the case 12 is formed along the outer shape of the induction device 11. According to this, the gap between the case 12 and the induction device 11 can be reduced, and the amount of the resin 29 filled in the case 12 can be reduced.

(4) According to the present embodiment, when the resin 29 is filled in the case 12, it is not necessary to fill the gap between the adjacent first and

second coils

31, 32 with the resin 29. Therefore, when the resin 29 flows into the gap between the adjacent first and

second coils

31 and 32, the air is confined in the gap and the air is interposed between the adjacent first and

second coils

31 and 32. Remaining as air bubbles is suppressed. As a result, it is possible to suppress the occurrence of variations in heat dissipation from the induction device 11 to the case 12 due to the remaining air bubbles.

(5) Since a part of the first coil 31 and a part of the second coil 32 are in contact with the pair of spacers 51, the heat generated from the first and

second coils

31 and 32 is transmitted through the spacers 51. Can be transmitted to the first core 21. Then, the heat transmitted to the first core 21 is dissipated to the case 12, whereby the temperature rise of the induction device 11 can be suppressed.

(6) Since the amount of resin 29 filled in the case 12 can be reduced, the time for filling the resin 29 in the case 12 can be shortened, and the manufacturing time of the reactor device 10 can be shortened. .

The above embodiment may be modified as follows.
As shown in the second embodiment of FIG. 6, the pair of spacers 51 may be integrally formed with the first core 21 so as to protrude from the first core 21 in the thickness direction. According to this, for example, each spacer 51 can be simultaneously molded with the first core 21 by using two kinds of materials of magnetic powder mixed resin and resin, so that the reactor device 10 can be easily manufactured. it can. In this case, the flat plate portion 41 a of the first bobbin 41 is formed with a notch 41 k along the outer shape of the corresponding spacer 51.

○ As shown in the third embodiment of FIG. 7, the first bobbin 41, the second bobbin 42, the first core 21 and the second core 22 are separated between the adjacent first and

second coils

31, 32. You may arrange a pair of spacer 51 which is a body. According to this, it is possible to use the existing first bobbin 41, the second bobbin 42, the first core 21 and the second core 22 which are separate from the spacer 51.

○ As shown in the fourth embodiment of FIG. 8, the first bobbin 41, the second bobbin 42, the first core 21, and the second core are disposed in the entire gap between the adjacent first and

second coils

31, 32. One spacer 51 separate from 22 may be disposed. In this case, the spacer 51 may further have a lower bottom 51a instead of the upper bottom 51b. In this case, in the spacer 51, a recess 33a having a shape corresponding to the connecting portion 33 needs to be formed in a portion overlapping with the connecting portion 33.

In each of the first to third embodiments, the number of the spacers 51 may not be two, and may be at least one.
In each of the above embodiments, the first core 21 may have a shape different from that of the second core 22.

In each of the above embodiments, the first coil 31 and the second coil 32 may have an elliptical ring shape or a square ring shape.
In each of the above embodiments, the induction device 11 may have the first coil 31 and the second coil 32 wound around one core.

In each of the above embodiments, the induction device 11 may have three or more cores.
In each of the above embodiments, the induction device 11 may have three or more coils.

In each of the above embodiments, the case 12 may have, for example, a bottomed square box shape.
In each of the above embodiments, the resin 29 may be a urethane resin or a silicone resin.

In each of the above embodiments, the first bobbin 41 and the second bobbin 42 may be formed of a resin other than polyphenylene sulfide resin (PPS resin).
In each of the above embodiments, the first coil 31 and the second coil 32 may be wound round wires.

In each of the above embodiments, the resin 29 may cover the entire induction device 11.
In each of the above embodiments, the induction device 11 may be a device other than a reactor (for example, a transformer).

Claims

A core having a plurality of legs, and an induction device having a plurality of coils wound respectively on the legs;
A case for housing the induction device;
A resin filled in the case;
An electronic device, comprising: a resin spacer disposed in a gap between the coils radially adjacent to each other.
The induction device further comprises a bobbin attached to the core,
The coils are wound around the legs through the bobbins,
The electronic device according to claim 1, wherein the spacer is integrally formed on the bobbin.
The electronic device according to claim 1, wherein the spacer is integrally formed on the core.
The induction device further comprises a bobbin attached to the core,
The coils are wound around the legs through the bobbins,
The electronic device according to claim 1, wherein the spacer is separate from the bobbin and the core.
The electronic device according to any one of claims 1 to 4, wherein the case has an inner circumferential surface formed along at least a part of the outer shape of the induction device.
The electronic device according to any one of claims 1 to 5, wherein the spacer is in contact with a part of the coil.