WO2016114236A1 - コア部品、コア部品の製造方法、およびリアクトル - Google Patents

コア部品、コア部品の製造方法、およびリアクトル Download PDF

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Publication number
WO2016114236A1
WO2016114236A1 PCT/JP2016/050544 JP2016050544W WO2016114236A1 WO 2016114236 A1 WO2016114236 A1 WO 2016114236A1 JP 2016050544 W JP2016050544 W JP 2016050544W WO 2016114236 A1 WO2016114236 A1 WO 2016114236A1
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WIPO (PCT)
Prior art keywords
resin mold
core
core component
green compact
coupling agent
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/JP2016/050544
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English (en)
French (fr)
Japanese (ja)
Inventor
平林　辰雄
康二 西
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Wiring Systems Ltd
AutoNetworks Technologies Ltd
Sumitomo Electric Industries Ltd
Original Assignee
Sumitomo Wiring Systems Ltd
AutoNetworks Technologies Ltd
Sumitomo Electric Industries Ltd
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 Sumitomo Wiring Systems Ltd, AutoNetworks Technologies Ltd, Sumitomo Electric Industries Ltd filed Critical Sumitomo Wiring Systems Ltd
Priority to CN201680004648.3A priority Critical patent/CN107112115A/zh
Priority to US15/540,083 priority patent/US10748704B2/en
Publication of WO2016114236A1 publication Critical patent/WO2016114236A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/266—Fastening or mounting the core on casing or support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/005—Impregnating or encapsulating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/08—Cooling; Ventilating
    • H01F27/22—Cooling by heat conduction through solid or powdered fillings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/245—Magnetic cores made from sheets, e.g. grain-oriented
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support

Definitions

  • the present invention uses a core part used in a reactor used in a DC-DC converter for a vehicle mounted on an electric vehicle such as a hybrid vehicle or a component part of a power converter, a manufacturing method thereof, and a core part. Reactor related.
  • Patent Document 1 discloses a reactor used in a converter of a hybrid vehicle.
  • Patent Document 1 is a reactor that is used in a converter mounted on a vehicle such as a hybrid vehicle, and is formed by press-molding a coil formed by winding a coil in a spiral and a raw material powder containing soft magnetic powder. What is provided with the magnetic core formed in cyclic
  • Patent Document 1 discloses a core component in which each powder compact is covered with an insulating coating layer (resin mold portion), a core component in which a plurality of powder compacts are integrally covered with a resin mold portion, and the like. Yes.
  • a core component that is excellent in bondability between a green compact and a resin mold part is desired.
  • ⁇ ⁇ ⁇ Coils in magnetic components generate heat due to Joule heat when energized and do not generate heat when de-energized.
  • the energizing current value is large, such as a reactor used in an in-vehicle converter, the heat generation of the coil is large. Therefore, the compacting body and the resin mold part arrange
  • positioned in the coil vicinity receive the heat cycle resulting from a coil, and are thermally expanded / contracted. Since the thermal expansion coefficient is different between the powder molded body mainly made of metal such as iron and the resin, the resin mold portion may be peeled off from the powder molded body due to thermal expansion and contraction.
  • the insulation between the green compact and the coil may be insufficient, or the gap length provided between the green compact may vary.
  • the magnetic characteristics of the reactor are impaired.
  • the resin mold part is peeled off and the integration of the plurality of green compacts is insufficient, the resonance frequency before and after peeling is changed, and there is a possibility that vibration and noise are increased as compared with those before peeling.
  • the present invention has been made in view of the above circumstances, and one of its purposes is to provide a core component in which a green compact and a resin mold part are firmly joined. Another object of the present invention is to provide a method of manufacturing a core component that is excellent in bondability with a resin mold portion. Furthermore, the other object of this invention is to provide the reactor using the core components excellent in bondability with the resin mold part.
  • the reactor which concerns on 1 aspect of this invention is equipped with the compacting body formed by pressure-molding the raw material powder containing soft-magnetic powder, and the resin mold part formed in the surface of the said compacting body, Reactor A core component that is a part of a magnetic core disposed inside and outside the coil included in the battery, and includes an intermediate layer formed of a silane coupling agent between the powder compact and the resin mold part.
  • a method for manufacturing a core part according to an aspect of the present invention includes a step ⁇ for preparing a powder compact formed by pressure-molding a raw material powder containing soft magnetic powder, and a surface of the powder compact with a silane coupling. And a process ⁇ for forming a resin mold part on the surface of the green compact processed with the silane coupling agent.
  • the reactor according to an aspect of the present invention is a reactor including an assembly including a coil and a magnetic core, and the magnetic core includes a core component according to an aspect of the present invention.
  • the core part is excellent in the bondability between the green compact and the resin mold part formed on the surface.
  • the above core component manufacturing method can produce a core component that is excellent in bondability with the resin mold part.
  • the above reactor is a reactor using a core component that is excellent in bondability with the resin mold part.
  • FIG. 3 is a schematic cross-sectional view of a core component shown in the first embodiment. It is the schematic of the chemical structure of a silane coupling agent. It is a schematic explanatory drawing explaining the formation method of a resin mold part. It is a schematic upper perspective view of the reactor of Embodiment 2. It is a disassembled perspective view of the union body with which the reactor of Embodiment 2 is equipped. It is a schematic longitudinal cross-sectional view of the 1st core component provided with a structure different from the 1st core component shown in FIG.
  • the core component of ⁇ 1> embodiment is provided with the compacting body formed by pressure-molding the raw material powder containing soft-magnetic powder, and the resin mold part formed in the surface of the said compacting body, A reactor A core component that is a part of a magnetic core disposed inside and outside the coil included in the battery, and includes an intermediate layer formed of a silane coupling agent between the powder compact and the resin mold part.
  • the green compact and the resin mold part can be firmly bonded via the intermediate layer formed of the silane coupling agent. Since the silane coupling agent chemically bonds with the surface of the green compact and also with the resin mold part, the bonding between the green compact and the resin mold part via the intermediate layer is extremely strong. It is.
  • the resin mold portion includes a bonding aid that strengthens the bonding between the intermediate layer and the resin mold portion, and the bonding aid includes an epoxy group, a carboxyl group, and an acid.
  • the form which has at least 1 sort (s) of functional group selected from an anhydride group, an amino group, and an isocyanate group can be mentioned.
  • the bonding between the intermediate layer and the resin mold part can be strengthened by including a bonding aid having a functional group chemically bonded to the silane coupling agent in the resin forming the resin mold part.
  • a bonding aid having a functional group chemically bonded to the silane coupling agent in the resin forming the resin mold part can be made even stronger.
  • the binding aid contained in the resin remains in the resin mold part.
  • a method for manufacturing a core component includes a step ⁇ for preparing a compact formed by pressing a raw material powder containing soft magnetic powder, and a surface of the compact formed body with a silane coupling agent. And a step ⁇ of forming a resin mold part on the surface of the green compact processed with the silane coupling agent.
  • the core component manufacturing method it is possible to manufacture the core component of the embodiment in which the intermediate layer is formed between the compacting body and the resin mold portion to firmly bond both.
  • the reactor of ⁇ 4> embodiment is a reactor provided with the assembly which has a coil and a magnetic core, Comprising:
  • the said magnetic core contains the core components which concern on embodiment.
  • FIG. 1 is a schematic cross-sectional view of a core component 10 according to an embodiment.
  • the core component 10 becomes a part of a magnetic core disposed inside and outside the coil provided in the reactor.
  • the core component 10 includes a green compact 11 that is a magnetic member and a resin mold portion 12 formed on the surface thereof. Further, the core component 10 includes an intermediate layer 13 formed between the green compact 11 and the resin mold portion 12.
  • the green compact 11 provided in the core part 10 is obtained by press molding raw material powder containing soft magnetic powder.
  • Soft magnetic powder is an aggregate of magnetic particles composed of an iron group metal such as iron or an alloy thereof (Fe—Si alloy, Fe—Ni alloy, etc.).
  • the average particle diameter (D50) of the magnetic particles is preferably 1 ⁇ m or more and 1000 ⁇ m or less, particularly preferably 10 ⁇ m or more and 500 ⁇ m or less.
  • An insulating coating made of phosphate or the like of 10 nm or more and 1 ⁇ m or less may be formed on the surface of the magnetic particles.
  • the raw material powder may contain a lubricant such as stearamide and a binder such as silicone resin. The lubricant and the binder may be lost during the heat treatment of the green compact to be described later.
  • the overall shape of the green compact 11 is typically a rectangular parallelepiped shape shown in FIG. 1, but is not particularly limited.
  • the green compact 11 may have a cylindrical shape, or may have a substantially semi-cylindrical shape like an outer core portion shown in the second embodiment described later.
  • the resin mold part 12 should just cover at least one part of the outer periphery of the compacting body 11, it is preferable to cover the perimeter of the compacting body 11. However, it may be configured such that a part of the outer periphery of the green compact 11 is not covered with the resin mold portion 12 depending on where the core component 10 is arranged on the magnetic core.
  • the second core part 320 (see FIG. 5) of the second embodiment to be described later is an example of a configuration in which a part of the outer core part 32 (a green compact) is exposed from the resin mold part 320m.
  • a plurality of powder compacts 11 may be integrated together by the resin mold portion 12.
  • the first core component 310 (see FIG. 5) of the second embodiment to be described later is an example of a configuration in which a plurality of divided cores 31m (a green compact) are covered with a resin mold portion 310m.
  • Examples of the resin constituting the resin mold portion 12 include polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin such as nylon 6, nylon 66, and polybutylene terephthalate.
  • Thermoplastic resins such as (PBT) resin and acrylonitrile / butadiene / styrene (ABS) resin can be used.
  • thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins can be used. These resins may contain a ceramic filler such as alumina or silica to improve the heat dissipation of the resin mold portion 12.
  • the resin mold part 12 may further contain a bonding aid that strengthens the bonding between the intermediate layer 13 and the resin mold part 12 described later.
  • the binding aid will be described again in the item of the intermediate layer 13.
  • the intermediate layer 13 provided in the core component 10 is a layer that firmly bonds the both 11 and 12 between the surface of the green compact 11 and the resin mold portion 12.
  • the intermediate layer 13 is formed of a silane coupling agent, and is chemically bonded to the surface of the green compact 11 and is also chemically bonded to the resin mold portion 12.
  • FIG. OR in the figure is a hydrolyzable group (OCH 3 , OC 2 H 5 , OCOCH 3 etc.), and Y in the figure is also a reactive functional group (amino group, epoxy group, methacryl group, vinyl group, mercapto group). Etc.).
  • the hydrolyzable group chemically bonds to the surface of the green compact 11 through a hydrogen bond with a hydroxyl group on the surface of the green compact 11 and a dehydration condensation polymerization reaction.
  • the reactive functional group chemically bonds with the functional group of the resin mold part 12.
  • the green compact 11 and the resin mold part 12 are firmly joined by the intermediate layer 13 formed of the silane coupling agent.
  • the resin mold part 12 includes a binding aid having a functional group that easily forms a chemical bond with the reactive functional group of the silane coupling agent that forms the intermediate layer 13, the intermediate layer 13 and the resin mold part 12 are included. Can be made stronger.
  • the functional group that is easily chemically bonded to the reactive functional group of the silane coupling agent include an epoxy group, a carboxyl group, an acid anhydride group, an amino group, and an isocyanate group. That is, it is preferable to use a binding aid having at least one of the above functional groups as a binding aid.
  • binding aid examples include maleic anhydride modified ethylene copolymer, glycidyl methacrylate modified ethylene copolymer, glycidyl ether modified ethylene copolymer, epoxy resin, isocyanate compound and the like.
  • the core component 10 includes a process ⁇ for preparing a powder compact 11 formed by pressure-molding a raw material powder containing soft magnetic powder, and a process ⁇ for treating the surface of the powder compact 11 with a silane coupling agent. And a step ⁇ for forming the resin mold portion 12 on the surface of the green compact 11 treated with the silane coupling agent.
  • the green compact 11 can be obtained by a known method for producing a green compact. That is, the powder compact 11 can be obtained by filling the raw material powder containing the soft magnetic powder into the mold cavity and press-molding the raw material powder. As the raw material powder, those already described in the item of the green compact 11 can be used. The pressure of the pressure molding of the raw material powder can be 390 MPa or more and 1500 MPa or less.
  • the conditions for the heat treatment are 400 ° C. or more and 700 ° C. or less, and 30 minutes or more and 60 minutes or less.
  • a treatment liquid containing a silane coupling agent is applied to the surface of the green compact 11 or the green compact is applied to the treatment liquid. 11 may be immersed.
  • the solvent for the silane coupling agent may be water or a water-soluble organic solvent such as ethanol or acetone.
  • the concentration of the silane coupling agent in the solution can be selected as appropriate.
  • the content of the silane coupling agent in the treatment liquid is preferably 0.05% by mass to 2.0% by mass, or 0.1% by mass to 1.5% by mass.
  • the content of the silane coupling agent is less than 0.05% by mass, the sufficient intermediate layer 13 is not formed.
  • the silane coupling agent layer is formed in multiple layers, so that there is a possibility that peeling occurs between the silane coupling agent layers.
  • the surface of the green compact 11 is preferably pretreated with an alkaline solution or an acidic solution.
  • the pretreatment is for generating a functional group (hydroxyl group) advantageous for reaction with the silane coupling agent on the surface of the green compact 11.
  • the alkaline solution include aqueous solutions of sodium hydroxide, potassium hydroxide, sodium carbonate and the like.
  • the acidic solution include hydrochloric acid, nitric acid, phosphoric acid, and sulfuric acid solutions.
  • a mold 6 shown in FIG. 3 In order to form the resin mold part 12 on the surface of the green compact 11, for example, a mold 6 shown in FIG. 3 can be used.
  • the molding die 6 includes holding members 60 and 60 that hold the powder compact 11 in a state of being separated from the inner peripheral surface thereof, and an injection port 61 that injects a resin into the molding die 6.
  • the resin spreads along the outer periphery of the green compact 11 as shown by the thick arrow in the figure, and the resin mold portion 12 shown in FIG. 1 can be formed.
  • an intermediate layer 13 derived from the silane coupling agent is formed between the green compact 11 and the resin mold part 12.
  • the resin constituting the resin mold portion 12 contains a binding aid.
  • a binding aid in the resin, when the resin is cured, the bonding between the intermediate layer 13 and the resin mold portion 12 can be strengthened. Since the optimal content of the binding aid in the resin varies depending on the type of resin, the type of binding aid, and the type of silane coupling agent, it cannot be determined in general. For example, when the total mass of the resin and the binding aid is 100, it may be 1% to 50% by mass, 2% to 25% by mass.
  • ⁇ Test example ⁇ A plurality of green compacts 11 were prepared, and samples 1 to 7 (core components 10) in which the resin mold portion 12 was formed on the surface of each green compact 11 were produced.
  • the green compacts 11 of Samples 1 to 7 have the same configuration.
  • the material used for forming the resin mold part 12 of each sample 1 to 7 is any of the following.
  • the configurations of Samples 1 to 7 are shown in Table 1.
  • -Resin forming the resin mold part 12 PPS resin or PA9T resin (Kuraray Co., Ltd.
  • Binding aid Glycidyl methacrylate-modified ethylene copolymer (hereinafter referred to as Compound I) or maleic anhydride-modified ethylene copolymer (hereinafter referred to as Compound II)
  • Coupling agent A silane coupling agent having an amino group as a reactive functional group (hereinafter referred to as an amino coupling agent) or a silane coupling agent having an epoxy group as a reactive functional group (hereinafter referred to as an epoxy coupling agent) )
  • the bondability of samples 1 to 3 in which the resin mold part 12 includes a binding aid and the surface of the green compact 11 was treated with a silane coupling agent was evaluation A.
  • the bondability of the samples 5 and 7 in which the surface of the green compact 11 was treated with a silane coupling agent was evaluation B.
  • the bondability of Samples 4 and 6 in which the surface of the green compact 11 was not treated with the silane coupling agent although the resin mold part 12 contained a binding aid was Evaluation C. From these results, it became clear that the bondability between the green compact 11 and the resin mold part 12 is improved by treating the surface of the green compact 11 with a silane coupling agent. Further, in addition to the surface treatment of the powder compact 11 with the silane coupling agent, if the resin mold part 12 further contains a binding aid, the powder compact 11 and the resin mold part 12 can be further joined. It became clear that the sex improved.
  • a reactor 1 shown in FIG. 4 has a configuration in which an assembly 1 ⁇ having a coil 2 and a magnetic core 3 is fixed on a mounting plate 9 with a coupling layer 8.
  • the configuration of the core component 10 of the first embodiment is applied to the first core component 310 and the second core component 320 that configure the magnetic core 3 described later.
  • the coil 2 in the present embodiment includes a pair of winding portions 2A and 2B and a connecting portion 2R that connects both the winding portions 2A and 2B.
  • Each winding part 2A, 2B is formed in a hollow cylindrical shape with the same number of turns and the same winding direction, and is arranged in parallel so that the respective axial directions are parallel.
  • the connecting portion 2R is a portion bent in a U shape that connects the two winding portions 2A and 2B.
  • the coil 2 may be formed by spirally winding a single winding without a joint.
  • the windings 2A and 2B may be formed by separate windings, and the windings 2A and 2B You may form by joining the edge parts of a coil
  • Each winding part 2A, 2B of this embodiment is formed in a rectangular tube shape.
  • the rectangular tube-shaped winding parts 2A and 2B are winding parts whose end face shape is a square shape (including a square shape) with rounded corners.
  • the winding portions 2A and 2B may be formed in a cylindrical shape.
  • the cylindrical winding portion is a winding portion whose end face shape is a closed curved surface shape (an elliptical shape, a perfect circle shape, a race track shape, etc.).
  • the coil 2 including the winding portions 2A and 2B is a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor such as a flat wire or a round wire made of a conductive material such as copper, aluminum, magnesium, or an alloy thereof. Can be configured.
  • the windings 2A and 2B are formed by edgewise winding a rectangular wire made of copper and a conductor made of enamel (typically polyamideimide). Yes.
  • Both end portions 2a and 2b of the coil 2 are extended from the winding portions 2A and 2B and connected to the terminal members 7 and 7, respectively.
  • An external device such as a power source for supplying power to the coil 2 is connected via the terminal members 7 and 7.
  • the magnetic core 3 in this example includes a pair of first core components 310 formed in a columnar shape, and a pair of second core components 320 and 320 that connect the end faces 310e and 310e of the first core components 310 and 310. .
  • the first core components 310 and 310 and the second core components 320 and 320 are connected in a ring shape, so that the magnetic core 3 is formed.
  • the 1st core component 310 is a member provided with the inner core part 31 arrange
  • the inner core portion 31 is configured by alternately laminating a plurality of divided core pieces 31m and a plurality of gap members 31g (an exploded perspective view of the inner core portion 31 surrounded by a two-dot chain line in the lower right). See also).
  • the divided core pieces 31m are compacted bodies formed by pressure-molding raw material powder containing soft magnetic powder.
  • the first core component 310 is a core component obtained by integrating a plurality of powder compacts (divided core pieces) with the resin mold part 310m, and the same configuration as the core component 10 of the first embodiment is adopted.
  • the gap material 31g is a member for adjusting the magnetic characteristics of the inner core portion 31, and can be made of alumina, for example.
  • the inner core portion 31 in which the split core pieces 31m and the gap material 31g are laminated is immersed in a treatment liquid of a silane coupling agent, and then a resin mold is formed on the surface of the inner core portion 31.
  • the portion 310m may be formed.
  • the intermediate layer 13 (see FIG. 1) is formed between the split core 31m (a green compact) of the inner core portion 31 and the resin mold portion 310m, and the resin mold portion 310m is formed from the inner core portion 31. It can suppress peeling.
  • the first core component 310 may be in the form shown in the longitudinal sectional view of FIG.
  • the first core component 310 (core component 10) shown in FIG. 6 has a configuration in which three divided core pieces 31m (a green compact 11) are arranged in a separated state and integrated by a resin mold portion 310m (12). Prepare.
  • the resin mold part 310m that has entered between the adjacent two divided core pieces 31m functions as a gap material.
  • the productivity of the first core component 310 can be improved.
  • middle layer 13 is formed in the perimeter of the division
  • the 2nd core component 320 is a member which covered the outer periphery of the outer core part 32 arrange
  • the outer core part 32 is comprised by the division
  • the same configuration as the core component 10 of the first embodiment is also applied to the second core component 320.
  • the resin mold part 320m may be formed on the surface of the split core piece 32m after the split core piece 32m is immersed in a treatment liquid of a silane coupling agent.
  • the intermediate layer 13 is formed between the split core piece 32m (compact compact) and the resin mold part 320m, and the resin mold part 320m is formed from the split core piece 32m (outer core part 32). It can suppress peeling.
  • the first core component 310 and the second core component 320 in this example are a thin portion 311 formed at the axial end of the first core component 310, a frame portion 321 formed at the second core component 320, Are connected by mechanical fitting.
  • the thin part 311 is a part formed by the resin mold part 310m being thinner than the other part, and the frame part 321 is a part formed by the resin mold part 320m protruding.
  • the outer core portion 32 is exposed inside the frame portion 321 without being covered by the resin mold portion 320m.
  • the end surface 310e of the first core component 310 and the end surface 32e of the outer core portion 32 (divided core piece 32m) of the second core component 320 are used. And contact.
  • An adhesive may be used between the end surface 310e and the end surface 32e.
  • the end surface 310 e is configured by a resin mold portion 310 m that covers the end surface 31 e of the inner core portion 31. Therefore, in this example, the resin mold part 310m functions as a gap material between the end face 31e of the inner core part 31 and the end face 31e of the outer core part 32.
  • the reactor 1 includes a mounting plate 9 and a bonding layer 8.
  • the mounting plate 9 is a member that functions as a base when the reactor 1 is fixed to an installation target such as a cooling base. For this reason, the mounting plate 9 is required to have excellent mechanical strength. Further, the mounting plate 9 is required to play a role of releasing heat generated in the combined body 1 ⁇ to the installation target when the reactor 1 is used. Therefore, the mounting plate 9 is required to have excellent heat dissipation in addition to mechanical strength. In order to meet such a demand, the mounting plate 9 is made of metal. For example, aluminum or an alloy thereof, magnesium or an alloy thereof can be used as a constituent material of the mounting plate 9. These metals (alloys) have the advantage of being excellent in mechanical strength and thermal conductivity, lightweight and non-magnetic.
  • a bonding layer 8 is formed between the mounting plate 9 and the combined body 1 ⁇ .
  • the bonding layer 8 also has a function of conducting heat generated in the combined body 1 ⁇ when the reactor 1 is used to the mounting plate 9.
  • the constituent material of the bonding layer 8 is assumed to have insulating properties.
  • thermosetting resins such as epoxy resins, silicone resins, and unsaturated polyesters, and thermoplastic resins such as PPS resins and LCPs can be used.
  • the heat dissipation of the bonding layer 8 may be improved by incorporating the above-described ceramic filler or the like into these insulating resins.
  • the thermal conductivity of the bonding layer 8 is preferably 0.1 W / m ⁇ K or more, more preferably 1 W / m ⁇ K or more, and particularly preferably 2 W / m ⁇ K or more.
  • the bonding layer 8 may be formed by applying an insulating resin (or a ceramic filler-containing resin) on the mounting plate 9, or affixing a sheet material of the insulating resin on the mounting plate 9. May be formed. It is preferable to use a sheet-like bonding layer 8 because the bonding layer 8 can be easily formed on the mounting plate 9.
  • the reactor according to the second embodiment is used in applications where the energization conditions are, for example, maximum current (direct current): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, and operating frequency: about 5 kHz to 100 kHz, typically an electric vehicle. It can be suitably used as a component part of a vehicle-mounted power conversion device such as a hybrid vehicle. In this application, it is expected that an inductance satisfying 10 ⁇ H or more and 2 mH or less of the inductance when the DC current is 0 A and 10% or more of the inductance when the maximum current is applied is 10% or more can be suitably used.
  • the core component of the present invention can be used for a reactor provided in a power conversion device such as a bidirectional DC-DC converter mounted on an electric vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle.
  • a power conversion device such as a bidirectional DC-DC converter mounted on an electric vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Soft Magnetic Materials (AREA)
  • Insulating Of Coils (AREA)
PCT/JP2016/050544 2015-01-13 2016-01-08 コア部品、コア部品の製造方法、およびリアクトル Ceased WO2016114236A1 (ja)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CN201680004648.3A CN107112115A (zh) 2015-01-13 2016-01-08 铁芯部件、铁芯部件的制造方法及电抗器
US15/540,083 US10748704B2 (en) 2015-01-13 2016-01-08 Core component, method for manufacturing core component, and reactor

Applications Claiming Priority (2)

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