WO2019181480A1 - リアクトル - Google Patents

リアクトル Download PDF

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Publication number
WO2019181480A1
WO2019181480A1 PCT/JP2019/008584 JP2019008584W WO2019181480A1 WO 2019181480 A1 WO2019181480 A1 WO 2019181480A1 JP 2019008584 W JP2019008584 W JP 2019008584W WO 2019181480 A1 WO2019181480 A1 WO 2019181480A1
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WO
WIPO (PCT)
Prior art keywords
core
hole
resin
winding
reactor
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/JP2019/008584
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English (en)
French (fr)
Japanese (ja)
Inventor
和宏 稲葉
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 US16/981,847 priority Critical patent/US20210118606A1/en
Priority to CN201980016616.9A priority patent/CN112041950B/zh
Publication of WO2019181480A1 publication Critical patent/WO2019181480A1/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
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2823—Wires
    • 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
    • H01F27/263—Fastening parts of the core together
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
    • 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
    • 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
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F3/14—Constrictions; Gaps, e.g. air-gaps
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • 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
    • H01F41/04—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 for manufacturing coils
    • H01F41/06—Coil winding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F2003/106—Magnetic circuits using combinations of different magnetic materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles

Definitions

  • the present disclosure relates to a reactor.
  • This application claims priority based on Japanese Patent Application No. 2018-052985 filed on Mar. 20, 2018, and incorporates all the contents described in the above Japanese application.
  • Patent Document 1 discloses a reactor that includes a coil having a winding portion formed by winding a winding and a magnetic core that forms a closed magnetic circuit, and is used as a component of a converter of a hybrid vehicle. ing.
  • the magnetic core of the reactor can be divided into an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion.
  • the reactor of the present disclosure is A coil having a winding part; A magnetic core having an inner core portion arranged inside the winding portion and an outer core portion arranged outside the winding portion, and a reactor,
  • the inner core part is an integral part of a non-divided structure, and includes a core through-hole penetrating in a direction orthogonal to the axial direction of the winding part, One opening and the other opening of the core through hole are both closed by the winding portion.
  • FIG. 1 is a perspective view of a reactor according to the first embodiment.
  • FIG. 2 is a schematic side view of the reactor of FIG.
  • FIG. 3 is a plan view of the magnetic core provided in the reactor of FIG. 1 as viewed from above.
  • FIG. 4 is a schematic top view of an inner core portion having a core through hole having a shape different from that of FIG.
  • FIG. 5 is a schematic top view of an inner core portion having a core through hole having a shape different from that of FIGS.
  • FIG. 6 is a schematic front view of the interposition member provided in the reactor of FIG.
  • FIG. 7 is a view showing a state in which the inner core portion and the outer core portion are combined with the interposition member shown in FIG.
  • FIG. 8 is an explanatory view illustrating the method for manufacturing the reactor according to the first embodiment.
  • This disclosure has been made in view of the above circumstances, and an object thereof is to provide a reactor that is excellent in productivity and hardly magnetically saturated.
  • the reactor of the present disclosure is a reactor that is excellent in productivity and hardly magnetically saturated.
  • the reactor according to the embodiment is A coil having a winding part; A magnetic core having an inner core portion arranged inside the winding portion and an outer core portion arranged outside the winding portion, and a reactor,
  • the inner core part is an integral part of a non-divided structure, and includes a core through-hole penetrating in a direction orthogonal to the axial direction of the winding part, One opening and the other opening of the core through hole are both closed by the winding portion.
  • the magnetic core can be configured only by combining the inner core part and the outer core part, and the productivity of the reactor can be improved. Further, by providing a core through hole penetrating in the direction perpendicular to the axial direction of the coil winding portion in the inner core portion, the core through hole can be used as a gap. As a result, by using the inner core portion having the core through-hole that functions as a gap, it is possible to suppress the relative permeability of the entire magnetic core from becoming too high, and to make the reactor difficult to be magnetically saturated.
  • the core through hole has a uniform inner peripheral surface shape in its axial direction,
  • the maximum width of the core through hole along the core width direction orthogonal to both the axial direction of the winding part and the axial direction of the core through hole is 0 of the width of the inner core part along the core width direction.
  • the form which is 1 time or more and 0.7 time or less can be mentioned.
  • the core through hole can function sufficiently as a gap. Moreover, even if it provides a core through-hole by making the said magnification into 0.7 times or less, the intensity
  • the inner peripheral surface shape of the core through hole is made into a perfect circle shape, or a long hole shape that is long in the axial direction of the winding part
  • the function as a gap of the core through-hole can be improved rather than.
  • an intermediate portion in the core width direction may have a narrowed shape.
  • the inner resin part By forming the inner resin part, it is possible to strengthen the coupling between the two while securing the insulation between the wound part and the inner core part. In addition, since the inner resin portion enters the core through hole, the coupling between the winding portion and the inner core portion can be further strengthened.
  • the outer core part can be protected from the external environment by forming the outer resin part. Further, since the outer resin portion is connected to the inner resin portion, the outer core portion, the inner core portion, and the winding portion can be firmly coupled.
  • the inner core has a relative magnetic permeability of 5 to 50
  • the outer core portion may have a relative magnetic permeability of 50 or more and 500 or less and higher than that of the inner core portion.
  • Leakage magnetic flux between both core portions can be reduced by making the relative permeability of the outer core portion higher than that of the inner core portion.
  • the leakage magnetic flux between both core portions can be more reliably reduced.
  • the leakage magnetic flux can be substantially eliminated.
  • the said inner core part can mention the form comprised with the molded object of the composite material containing soft-magnetic powder and resin.
  • the compact of the composite material is easy to reduce its relative permeability by adjusting the amount of soft magnetic powder. Therefore, in the case of a molded body of a composite material, it is easy to produce an inner core portion having a relative permeability satisfying the range of ⁇ 7>.
  • the said outer core part can mention the form comprised with the compacting body of a soft magnetic powder.
  • an outer core part can be produced with high accuracy. Moreover, if it is a compacting body which contains soft-magnetic powder densely, it will be easy to produce the outer core part with which a relative magnetic permeability satisfy
  • the relative permeability of the inner core part lower than that of the outer core part, it is possible to suppress the relative permeability of the entire magnetic core from becoming too high, and to reduce the magnetic saturation of the magnetic core.
  • the suppressing effect can be obtained.
  • the length of the central axis of the inner core portion occupying the length of the virtual magnetic path (the same as the axial length of the inner core portion) ) Is short, the magnetic saturation suppression effect is limited.
  • the ratio of the length of the central axis of the inner core portion to the length of the virtual magnetic path is 50% or less. If it exists, the effect of suppressing magnetic saturation cannot be obtained sufficiently.
  • the ratio of the length of the central axis of the inner core portion to the length of the virtual magnetic path is 50. Even if it is not more than%, the effect of suppressing magnetic saturation can be sufficiently obtained.
  • a reactor 1 shown in FIG. 1 is configured by combining a coil 2, a magnetic core 3, and an interposition member 4.
  • the reactor 1 is further disposed inside the winding portions 2A and 2B provided in the coil 2, and includes an inner resin portion 5 (see FIG. 2) that covers the inner core portion 31 that constitutes a part of the magnetic core 3, and the magnetic core 3
  • the outer resin part 6 which covers the outer core part 32 which comprises a part of this is provided.
  • a core through hole 31 h is formed in the inner core portion 31.
  • the coil 2 includes a pair of winding parts 2A and 2B and a connecting part 2R that connects both the winding parts 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 coil 2 is manufactured by one winding, but the coil 2 can also be manufactured by connecting the winding portions 2A and 2B manufactured by separate windings.
  • the gaps between adjacent turns of the winding parts 2A and 2B are substantially uniform. That is, the winding portions 2A and 2B have a constant coil pitch, and since there is no portion where the coil pitch is locally widened, the winding portions 2A and 2B can be easily manufactured.
  • the gap between turns is preferably substantially zero.
  • the direction in the reactor 1 is defined based on the coil 2.
  • the direction along the axial direction of winding part 2A, 2B of the coil 2 be an X direction.
  • a direction perpendicular to the X direction and along the parallel direction of the winding portions 2A and 2B is defined as a Y direction.
  • a direction intersecting both the X direction and the Y direction is taken as a Z direction.
  • 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.
  • each winding portion 2A, 2B is formed by edgewise winding a coated rectangular wire made of a copper rectangular wire (winding) and an insulating coating made of enamel (typically polyamideimide). Is forming.
  • Both end portions 2a and 2b of the coil 2 are extended from the winding portions 2A and 2B and connected to a terminal member (not shown).
  • the insulating coating such as enamel is peeled off at both ends 2a and 2b.
  • An external device such as a power source for supplying power is connected to the coil 2 through the terminal member.
  • the magnetic core 3 includes inner core portions 31 and 31 disposed inside the winding portions 2 ⁇ / b> A and 2 ⁇ / b> B, and an outer core that forms a closed magnetic path with the inner core portions 31 and 31. Parts 32, 32.
  • the inner core portion 31 is a portion of the magnetic core 3 along the axial direction (X direction) of the winding portions 2A and 2B of the coil 2.
  • both end portions of the magnetic core 3 along the axial direction of the winding portions 2A and 2B protrude from the end faces of the winding portions 2A and 2B (inner core portion). (See the position of the end face 31e of 31).
  • the protruding portion is also a part of the inner core portion 31.
  • the shape of the inner core portion 31 is not particularly limited as long as it is a shape along the inner shape of the winding portion 2A (2B).
  • the inner core portion 31 in this example has a substantially rectangular parallelepiped shape.
  • the inner core portion 31 of this example is an undivided structure and includes a core through hole 31h.
  • the core through hole 31h is a hole that penetrates the inner core portion 31 in the height direction (Z direction) of the reactor 1 orthogonal to the axial direction (X direction) of the winding portions 2A and 2B. Function as.
  • the core through hole 31h may be a hole extending along the YZ plane orthogonal to the X direction.
  • the core through hole 31h may be a hole that penetrates the inner core portion 31 in the parallel direction (Y direction) of the winding portions 2A and 2B. it can.
  • the core through hole 31h preferably has a uniform inner peripheral surface shape in the axial direction (Z direction), and by doing so, the function of the core through hole 31h as a gap can be stabilized.
  • one core through hole 31h is provided at the axial center position of the inner core portion 31, but the number of core through holes 31h is not particularly limited.
  • a plurality of core through-holes 31h may be provided in one inner core portion 31, but if there are too many core through-holes 31h, the strength and magnetic properties of the inner core portion 31 may be reduced.
  • a plurality of core through holes 31h are provided in the inner core portion 31, for example, in the vicinity of the end surface 31e on the one end side in the axial direction of the inner core portion 31 and in the vicinity of the end surface 31e on the other end side.
  • One example is providing the core through holes 31h one by one. If there is no problem in the strength and magnetic characteristics of the inner core portion 31, the core through hole 31h can be freely provided.
  • the plurality of core through holes 31h can be arranged so as to intersect each other when viewed from the X direction.
  • Both one opening and the other opening of the core through hole 31h are closed by the winding portions 2A and 2B.
  • This is a state in which when the openings of the core through holes 31h are viewed in the axial direction from the outer periphery of the winding parts 2A and 2B, the turns of the winding parts 2A and 2B overlap 50% or more of the area of the opening.
  • the overlapping area is preferably as large as possible, and can be, for example, 60% or more, and further 70% or more.
  • the large overlap area means that the gap between the turns of the winding parts 2A and 2B is small, and the reactor 1 can be miniaturized in the X direction, and inside the winding parts 2A and 2B as described later.
  • the overlapping area is preferably 90% or more, and more preferably 95% or more. Since the core through hole 31h is covered with the winding portions 2A and 2B, loss due to leakage magnetic flux can be suppressed.
  • the inner peripheral surface shape (same as the shape of the opening) of the core through hole 31h is preferably a long hole shape extending in the core width direction (Y direction) as shown in FIG. Since the inner peripheral surface shape of the core through hole 31h is longer in the core width direction, the function of the core through hole 31h as a gap can be improved.
  • As the long hole shape a rectangular shape or an elliptical shape, or a pair of linear portions extending in the core width direction as shown in FIG. 3, an arc portion connecting one end of both linear portions, and the other ends of both linear portions
  • a racetrack shape formed by connecting arc portions and the like can be mentioned.
  • the flow of magnetic flux bypassing the core through hole 31h becomes smooth, and the inner core portion 31 having excellent magnetic characteristics can be obtained.
  • the maximum width L W1 along the core width direction (Y direction) of the core through hole 31h is 0.1 to 0.7 times the width L W of the inner core portion 31 along the core width direction. preferable.
  • the core through hole 31h can function sufficiently as a gap.
  • the width of the substantial portion 31R of the inner core portion 31 on the outer side in the width direction can be sufficiently secured.
  • the mechanical strength of the inner core portion 31 can be sufficiently secured.
  • a more preferable magnification is 0.2 times or more and 0.6 times or less, and a still more preferable magnification is 0.3 times or more and 0.5 times or less.
  • the Z direction is the core width direction.
  • the maximum width LW2 along the axial direction (X direction) of the winding portions 2A and 2B of the core through hole 31h is not particularly limited.
  • the maximum width L W2 in the X direction of the core through holes 31h can be appropriately selected depending on the degree of function as a gap required for the core through-hole 31h.
  • both the one opening and the other opening of the core through hole 31h of this example need to be closed by the winding portions 2A and 2B.
  • the winding portion 2A, the gap between 2B adjacent turns of the (or coil pitch) less than 10% of the maximum width L W2 in the X direction of the core through holes 31h (or 10%), further Is 5% or less (or 5% or less).
  • the intermediate portion 310 in the core width direction (Y direction) of the inner peripheral surface shape of the core through hole 31h is narrowed.
  • the shape can also be changed. Since the intermediate portion 310 of the core through hole 31h has a narrowed shape, a part of the magnetic flux when the reactor 1 (FIG. 1) is operated easily passes through the narrowed portion (intermediate portion 310) of the core through hole 31h. Become. As a result, it is possible to prevent the magnetic flux passing through the substantial part 31R of the inner core part 31 from being too large by avoiding the core through-hole 31h, and to suppress the substantial part 31R from being magnetically saturated. Furthermore, as shown in FIG.
  • the intermediate portion 311 in the X direction can also be narrowed. With such a shape, the substantial portion 31R becomes large at the position of the intermediate portion 311, and it is easy to suppress the substantial portion 31R from being magnetically saturated.
  • the outer core portion 32 shown in FIG. 1 is a portion of the magnetic core 3 that is disposed outside the winding portions 2A and 2B.
  • the shape of the outer core part 32 will not be specifically limited if it is a shape which connects the edge part of a pair of inner core parts 31 and 31.
  • FIG. The outer core portion 32 in this example has a substantially rectangular parallelepiped shape.
  • the outer core portion 32 includes a coil facing surface 32e facing the end surfaces of the winding portions 2A and 2B of the coil 2, an outer surface 32o opposite to the coil facing surface 32e, and a circumferential surface 32s. And having.
  • the coil facing surface 32 e of the outer core portion 32 and the end surface 31 e of the inner core portion 31 are in contact with each other or substantially in contact with an adhesive.
  • the relative permeability of the inner core portion 31 is 5 or more and 50 or less
  • the relative permeability of the outer core portion 32 is 50 or more and 500 or less, and higher than the relative permeability of the inner core portion 31.
  • the relative magnetic permeability of the inner core portion 31 can further be 10 or more and 45 or less, 15 or more and 40 or less, and 20 or more and 35 or less.
  • the relative magnetic permeability of the outer core portion 32 can be further set to 80 or more, 100 or more, 150 or more, 180 or more.
  • the relative magnetic permeability of the core portions 31 and 32 for example, by setting the relative permeability of the outer core portion 32 to be twice or more the relative permeability of the inner core portion 31,
  • the leakage magnetic flux between 32 can be substantially eliminated.
  • the relative magnetic permeability of the inner core part 31 is low compared with the relative magnetic permeability of the outer core part 32, it can suppress that the relative magnetic permeability of the magnetic core 3 whole becomes high too much, and the magnetism of a gapless structure
  • the core 3 can be used.
  • the inner core portion 31 and the outer core portion 32 are made of a compact formed by pressing a raw material powder containing soft magnetic powder, or a composite material obtained by curing a mixture of soft magnetic powder and uncured resin. It can be comprised with a molded object.
  • the soft magnetic powder of the green compact is an aggregate of soft magnetic particles composed of an iron group metal such as iron or an alloy thereof (Fe—Si alloy, Fe—Ni alloy, etc.).
  • An insulating coating made of phosphate or the like may be formed on the surface of the soft magnetic particles.
  • the raw material powder may contain a lubricant.
  • thermosetting resin examples include unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins.
  • Thermoplastic resins include polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin such as nylon 6 and nylon 66, polybutylene terephthalate (PBT) resin, acrylonitrile butadiene -Styrene (ABS) resin etc. are mentioned.
  • PPS polyphenylene sulfide
  • PTFE polytetrafluoroethylene
  • LCP liquid crystal polymer
  • PA polyamide
  • PBT polybutylene terephthalate
  • ABS acrylonitrile butadiene -Styrene
  • BMC Bulk molding compound in which calcium carbonate or glass fiber is mixed with unsaturated polyester, millable silicone rubber, millable urethane rubber, or the like can also be used.
  • the above-mentioned composite material contains non-magnetic and non-metallic powder (filler) such as alumina and silica in addition to the soft magnetic powder and the resin, the heat dissipation is further improved.
  • the content of the non-magnetic and non-metallic powder is 0.2% by mass or more and 20% by mass or less, further 0.3% by mass or more and 15% by mass or less, and 0.5% by mass or more and 10% by mass or less.
  • the content of the soft magnetic powder in the composite material is 30% by volume or more and 80% by volume or less. From the viewpoint of improving the saturation magnetic flux density and heat dissipation, the content of the magnetic powder can be further 50% by volume or more, 60% by volume or more, and 70% by volume or more. From the viewpoint of improving the fluidity in the production process, the content of the magnetic powder is preferably 75% by volume or less.
  • the relative permeability can be easily reduced by adjusting the filling rate of the soft magnetic powder to be low. Therefore, the composite material molded body is suitable for manufacturing the inner core portion 31 having a relative permeability of 5 to 50.
  • the inner core portion 31 is made of a composite material, and its relative permeability is 20.
  • the green compact easily increases the content of soft magnetic powder (for example, more than 80% by volume, more than 85% by volume), and obtains a core piece having a higher saturation magnetic flux density and higher relative permeability than the composite material molded body. easy. Therefore, the green compact is suitable for producing the outer core portion 32 having a relative magnetic permeability of 50 or more and 500 or less.
  • the outer core portion 32 is formed of a powder compact, and the relative permeability is 200.
  • the ratio of the axial length (the length of the central axis 31L) of the inner core 31 to the length of the virtual magnetic path indicated by the two-dot chain line in FIG. 3 by forming the core through hole 31h in the inner core 31. Can be made 50% or less.
  • the virtual magnetic path schematically indicates the main path of the magnetic flux, and in the plan view of the magnetic core 3 when the magnetic core 3 is viewed from above, the similarity between the central axis 31L of the inner core portion 31 and the outer core portion 32 is similar.
  • the line 32L is connected in a ring shape.
  • the central axis 31 ⁇ / b> L is a line that passes through the center in the width direction of the inner core portion 31 and extends along the axial direction of the inner core portion 31.
  • the similarity line 32L is a line that passes through the center of gravity of the outer core portion 32 (see the cross in FIG. 3) in the plan view and draws a shape similar to the outer contour line of the outer core portion 32 and is connected to the central axis 31L.
  • the center of gravity is not the center of mass, but the center of gravity of the planar area of the outer core portion 32 in the plan view.
  • the outer contour line is a portion of the contour line of the outer core portion 32 excluding the line facing the inner core portion 31.
  • the actual magnetic path is shaped like a racetrack with curved corners of the similarity line 32L, but the actual magnetic path length and the virtual magnetic path length are not so different. Good. Therefore, defining the ratio of the central axis 31L in the length of the virtual magnetic path is synonymous with defining the ratio of the axial length of the inner core portion 31 in the length of the magnetic path.
  • the inner core portion occupies the length of the virtual magnetic path.
  • the ratio of the length of 31 central axis 31L is represented by ⁇ (2 ⁇ L C ) / (2 ⁇ L d + 2 ⁇ L C ) ⁇ ⁇ 100.
  • the reactor 1 can be downsized.
  • the ratio is 50% or less, the effect of suppressing magnetic saturation cannot be sufficiently obtained.
  • the ratio is preferably set to 30% or more.
  • the reactor 1 of this example shown in FIG. 1 further includes an interposition member 4 interposed between the coil 2 and the magnetic core 3.
  • the interposition member 4 is typically made of an insulating material and functions as an insulating member between the coil 2 and the magnetic core 3 and a positioning member for the inner core portion 31 and the outer core portion 32 with respect to the winding portions 2A and 2B.
  • the interposition member 4 in this example is a rectangular frame-shaped member, and also functions as a member that forms a resin flow path filling the winding portions 2A and 2B.
  • the interposition member 4 is not essential, but by using the interposition member 4, the above-described insulation can be easily secured and positioned.
  • FIG. 6 is a front view of the interposition member 4 as viewed from one surface side where the outer core portion 32 (FIG. 1) is disposed, and the other surface side where the winding portions 2A and 2B (FIG. 1) are disposed is the back of the page. Yes, I can't see.
  • FIG. 7 is a view showing a state in which the inner core portions 31 and one outer core portion 32 are assembled to the interposition member 4 in FIG. 6.
  • the interposition member 4 includes a pair of through holes 41h, 41h, a plurality of support portions 41 provided in each through hole 41h, a coil storage portion (not shown), a core storage portion 42, and the like. .
  • the through hole 41h penetrates in the thickness direction of the interposed member 4, and the inner core portion 31 is inserted into the through hole 41h as shown in FIG.
  • the inner peripheral surfaces forming the through holes 41h and 41h substantially coincide with the inner peripheral surfaces of the winding portions 2A and 2B (FIG. 1).
  • the support portion 41 partially protrudes from the inner peripheral surface of the through hole 41 h and supports the four corner portions of the inner core portion 31.
  • the coil storage portion is provided on the other surface side of the interposition member 4 that is not visible in the drawing, and the end surfaces of the winding portions 2A and 2B (FIG. 1) and the vicinity thereof are fitted.
  • the core housing part 42 is formed by a part of one surface side of the interposition member 4 being recessed in the thickness direction, and the coil facing surface 32e of the outer core part 32 and the vicinity thereof are fitted (see also FIG. 2).
  • An end surface 31e (FIG. 7) of the inner core portion 31 fitted in the through hole 41h of the interposition member 4 protrudes from the bottom surface of the core housing portion 42 (see also FIG. 8 described later). Therefore, the outer core part 32 fitted in the core storage part 42 is separated from the bottom part of the core storage part 42.
  • the gap formed by separating the outer core portion 32 and the bottom portion of the core storage portion 42 becomes a resin flow path as will be described later.
  • the winding portions 2A and 2B are fitted into the coil storage portion, and the inner core portions 31 and 31 are inserted into the through holes 41h and 41h, respectively.
  • Four resin filling holes h1, h2, h3, h4 communicating with the gap between the turning portions 2A, 2B and the inner core portion 31 are formed. More specifically, a resin filling hole h1 is formed between the upper end edge of the end surface 31e of the inner core portion 31 and the inner peripheral surface of the through hole 41h (FIG. 6), and the outer edge of the end surface 31e and the through hole 41h.
  • a resin filling hole h2 is formed between the inner peripheral surface of the resin.
  • a resin filling hole h3 is formed between the inner edge of the end surface 31e and the inner peripheral surface of the through hole 41h, and a resin filling hole is formed between the lower edge of the end surface 31e and the inner peripheral surface of the through hole 41h.
  • h4 is formed.
  • the resin filling holes h1 and h2 are not covered by the outer core portion 32, but the resin filling holes h3 and h4 are covered by the outer core portion 32.
  • the interposing member 4 includes, for example, polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin such as nylon 6 and nylon 66, polybutylene terephthalate (PBT) resin, acrylonitrile.
  • PPS polyphenylene sulfide
  • PTFE polytetrafluoroethylene
  • LCP liquid crystal polymer
  • PA polyamide
  • PCB polybutylene terephthalate
  • -It can be comprised with thermoplastic resins, such as a butadiene styrene (ABS) resin.
  • the interposition member 4 can be formed of a thermosetting resin such as an unsaturated polyester resin, an epoxy resin, a urethane resin, or a silicone resin.
  • These resins may contain a ceramic filler to improve the heat dissipation of the interposition member 4.
  • the ceramic filler for example, nonmagne
  • the inner resin portion 5 is disposed inside the winding portion 2 ⁇ / b> A (the same applies to the winding portion 2 ⁇ / b> B not shown), and the inner peripheral surface of the winding portion 2 ⁇ / b> A and the outer peripheral surface of the inner core portion 31. Join.
  • the inner resin part 5 it is possible to strengthen the coupling between the winding parts 2 ⁇ / b> A and 2 ⁇ / b> B and the inner core part 31 while ensuring insulation between the wound parts 2 ⁇ / b> A and 2 ⁇ / b> B and the inner core part 31.
  • the inner resin portion 5 stays inside the winding portion 2A without straddling between the inner peripheral surface and the outer peripheral surface of the winding portion 2A. That is, the outer peripheral surfaces of the winding portions 2A and 2B are exposed to the outside without being covered with resin as shown in FIG.
  • the inner resin portion 5 enters the core through hole 31h of the inner core portion 31 when filling the winding portions 2A and 2B.
  • the inner resin portion 5 that has entered the core through hole 31h serves as an anchor, and the coupling between the winding portions 2A and 2B and the inner core portion 31 can be further strengthened.
  • the inner resin part 5 is, for example, a thermosetting resin such as an epoxy resin, a phenol resin, a silicone resin, or a urethane resin, a thermoplastic resin such as a PPS resin, a PA resin, a polyimide resin, or a fluorine resin, a room temperature curable resin, or A low temperature curable resin can be used. These resins may contain ceramic fillers such as alumina and silica to improve the heat dissipation of the inner resin portion 5.
  • a thermosetting resin such as an epoxy resin, a phenol resin, a silicone resin, or a urethane resin
  • a thermoplastic resin such as a PPS resin, a PA resin, a polyimide resin, or a fluorine resin, a room temperature curable resin, or A low temperature curable resin can be used.
  • These resins may contain ceramic fillers such as alumina and silica to improve the heat dissipation of the inner resin portion 5.
  • the outer resin portion 6 is arranged so as to cover the entire outer peripheral surface exposed from the interposition member 4 in the outer core portion 32, and fixes the outer core portion 32 to the interposition member 4 and The core part 32 is protected from the external environment.
  • the outer resin part 6 in this example is connected to the inner resin part 5. That is, the outer resin part 6 and the inner resin part 5 are formed of the same resin at a time. Since the outer resin part 6 is connected to the inner resin part 5, the outer core part 32, the inner core part 31, and the winding parts 2A and 2B can be firmly joined.
  • the outer resin portion 6 of this example is provided on the side where the outer core portion 32 of the interposing member 4 is disposed, and does not reach the outer peripheral surfaces of the winding portions 2A and 2B.
  • the formation range of the outer resin part 6 is sufficient as shown in the figure, and is preferable in that the amount of resin used can be reduced.
  • the outer resin portion 6 may extend to the winding portions 2A and 2B.
  • the reactor 1 of this example can be used as a component of 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.
  • the reactor 1 of this example can be used in the state immersed in the liquid refrigerant.
  • the liquid refrigerant is not particularly limited, but when the reactor 1 is used in a hybrid vehicle, ATF (Automatic Transmission Fluid) or the like can be used as the liquid refrigerant.
  • fluorinated inert liquids such as Fluorinert (registered trademark), chlorofluorocarbon refrigerants such as HCFC-123 and HFC-134a, alcohol refrigerants such as methanol and alcohol, and ketone refrigerants such as acetone are used as liquid refrigerants.
  • Fluorinert registered trademark
  • chlorofluorocarbon refrigerants such as HCFC-123 and HFC-134a
  • alcohol refrigerants such as methanol and alcohol
  • ketone refrigerants such as acetone
  • the magnetic core 3 can be manufactured more easily than a form in which a plurality of divided pieces are combined.
  • the productivity of the reactor 1 including the production of the magnetic core 3 is improved. be able to.
  • the core through hole 31h functioning as a gap is formed in the inner core portion 31 of the present example, it is possible to suppress the relative permeability of the entire magnetic core 3 including the inner core portion 31 from becoming too high. As a result, when the reactor 1 is used with a large current, the magnetic core 3 is hardly magnetically saturated.
  • the reactor manufacturing method generally includes the following steps. ⁇ Coil manufacturing process ⁇ Assembly process ⁇ Filling process ⁇ Curing process
  • the coil 2 is prepared by preparing a winding and winding a part of the winding.
  • a known winding machine can be used for winding the winding.
  • the coil 2 may be heat-treated after a heat-sealing resin layer is formed on the surface of the winding and the winding is wound to form the winding portions 2A and 2B. In that case, each turn of winding part 2A, 2B can be integrated, and it is easy to perform the filling process mentioned later.
  • the coil 2, the magnetic core 3, and the interposition member 4 are combined.
  • the inner core portion 31 is disposed inside the winding portions 2A and 2B, and the pair of interposition members 4 and 4 are brought into contact with the one end side end surface and the other end side end surface of the winding portions 2A and 2B, respectively.
  • a first assembly is made.
  • interposed the 1st assembly with a pair of outer core part 32 is produced.
  • the end face 31e of the inner core portion 31 and the coil facing surface 32e of the outer core portion 32 can be joined with an adhesive or the like.
  • this assembly process can be easily performed.
  • the resin is filled into the winding parts 2A and 2B in the second assembly.
  • the second assembly is placed in the mold 7 and injection molding is performed in which a resin is injected into the mold 7.
  • Resin is injected from the two resin injection holes 70 of the mold 7.
  • the resin injection hole 70 is provided at a position corresponding to the outer surface 32o of the outer core portion 32, and the resin is injected from the outer side (outer surface 32o side) of each outer core portion 32.
  • the resin filled in the mold 7 covers the outer periphery of the outer core portion 32 and wraps around the outer peripheral surface of the outer core portion 32, so that the winding portions 2A, 2A, It flows into 2B.
  • the resin covering the outer core portion 32 flows into the gap between the coil facing surface 32e (such as FIG. 2) of the outer core portion 32 and the bottom portion of the core housing portion 42 of the interposition member 4, and further through the gap of FIG. It flows into the winding parts 2A and 2B through the resin filling holes h3 and h4.
  • the resin that has flowed into the winding portions 2A and 2B also flows into the core through hole 31h and fills the core through hole 31h.
  • the resin is cured by heat treatment or the like.
  • those inside the winding parts 2A and 2B become the inner resin part 5 as shown in FIG. 2, and those that cover the outer core part 32 become the outer resin part 6.
  • the reactor 1 shown in FIG. 1 can be manufactured.
  • the inside of winding part 2A, 2B is filled with sufficient resin by inflow of resin to winding part 2A, 2B, and inner resin formed inside winding part 2A, 2B It is difficult to form a large gap in the portion 5.
  • the inner resin part 5 and the outer resin part 6 are integrally formed, and the filling process and the curing process are performed only once, so the reactor 1 is manufactured with high productivity. be able to.
  • the reactor 1 of the first embodiment may be housed in a case and embedded in the case with potting resin.
  • the second assembly produced in the assembly process according to the reactor manufacturing method of Embodiment 1 is housed in a case, and potting resin is filled in the case.
  • the potting resin that covers the outer periphery of the outer core portion 32 becomes the outer resin portion 6.
  • the potting resin that has flowed into the winding parts 2A and 2B becomes the inner resin part 5.
  • the inner resin part 5 and the outer resin part 6 in the first and second embodiments may be omitted.
  • the reactor 1 may be completed by producing a first assembly of the coil 2, the magnetic core 3, and the interposition member 4, and integrating the first assembly with a band or the like.
  • the reactor 1 of this example is immersed in the liquid refrigerant, the liquid refrigerant enters the winding portions 2A and 2B from the gap between the turns of the winding portions 2A and 2B, and the inner core portion 31 is cooled.
  • the core through-hole 31h not only functions as a gap but also functions as a passage for the refrigerant, and can cool the inner core portion 31 effectively.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Dispersion Chemistry (AREA)
  • Composite Materials (AREA)
  • Dc-Dc Converters (AREA)
  • Soft Magnetic Materials (AREA)
  • Insulating Of Coils (AREA)
PCT/JP2019/008584 2018-03-20 2019-03-05 リアクトル Ceased WO2019181480A1 (ja)

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JP2006351920A (ja) * 2005-06-17 2006-12-28 Toyota Motor Corp リアクトル
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WO2013137019A1 (ja) * 2012-03-13 2013-09-19 住友電気工業株式会社 リアクトル、コンバータ、および電力変換装置
JP2015126145A (ja) * 2013-12-26 2015-07-06 株式会社オートネットワーク技術研究所 リアクトル
JP2015142122A (ja) * 2014-01-30 2015-08-03 Ｊｆｅスチール株式会社 リアクトル
JP2017212346A (ja) * 2016-05-25 2017-11-30 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

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JP2006351920A (ja) * 2005-06-17 2006-12-28 Toyota Motor Corp リアクトル
WO2011111257A1 (ja) * 2010-03-09 2011-09-15 三菱電機株式会社 静止器
WO2013137019A1 (ja) * 2012-03-13 2013-09-19 住友電気工業株式会社 リアクトル、コンバータ、および電力変換装置
JP2015126145A (ja) * 2013-12-26 2015-07-06 株式会社オートネットワーク技術研究所 リアクトル
JP2015142122A (ja) * 2014-01-30 2015-08-03 Ｊｆｅスチール株式会社 リアクトル
JP2017212346A (ja) * 2016-05-25 2017-11-30 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

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CN112041950A (zh) 2020-12-04

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