WO2021153135A1 - リアクトル、及びリアクトルの冷却構造 - Google Patents

リアクトル、及びリアクトルの冷却構造 Download PDF

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Publication number
WO2021153135A1
WO2021153135A1 PCT/JP2020/048872 JP2020048872W WO2021153135A1 WO 2021153135 A1 WO2021153135 A1 WO 2021153135A1 JP 2020048872 W JP2020048872 W JP 2020048872W WO 2021153135 A1 WO2021153135 A1 WO 2021153135A1
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Prior art keywords
magnetic
reactor
core
magnetic material
coil conductor
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PCT/JP2020/048872
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English (en)
French (fr)
Japanese (ja)
Inventor
秀二 木原
肇 川口
Original Assignee
株式会社村田製作所
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Priority to JP2021574558A priority Critical patent/JP7345738B2/ja
Publication of WO2021153135A1 publication Critical patent/WO2021153135A1/ja

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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
    • H01F27/24—Magnetic cores
    • 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

Definitions

  • the present invention relates to a reactor and a cooling structure of the reactor, and more particularly, it is emitted from a coil conductor having a coil conductor in which a conducting wire is wound so as to have a hollow portion, a reactor having a magnetic core containing a magnetic material, and the coil conductor. It relates to a reactor cooling structure that dissipates heat and cools it.
  • the reactor is a passive element that uses inductance, and has been installed in various electronic devices as an element of circuit elements in recent years.
  • an inverter mounted on a vehicle such as an electric vehicle, a hybrid vehicle, or a fuel cell vehicle incorporates a converter that boosts or lowers the battery voltage, and the reactor is used as a core component of the converter.
  • Patent Document 1 proposes a coil component used as a reactor as shown in FIG. 35. That is, Patent Document 1 has a coil-encapsulated insulating enclosure 104 obtained by enclosing a coil conductor 102 with an insulator 101 made of a first resin so as to remove ends 103a and 103b, and includes the coil.
  • the insulating enclosure 104 is embedded inside a magnetic core core 105 made of a mixture of a powder containing at least a magnetic powder and a second resin.
  • Patent Document 1 in order to ensure consistency with the elastic modulus and linear expansion coefficient of the magnetic core core 105, a non-magnetic filler such as silica powder or alumina powder is added to the first resin to provide an insulator 101. Is described to form.
  • Patent Document 1 good withstand voltage characteristics and withstand-use pulse current performance are ensured by surrounding the coil conductor 102 with an insulator 101. Further, the insulator 101 is embedded inside the magnetic core core 105 to fix the movement of the coil conductor 102 so that vibration such as audible noise and groaning does not occur even if the coil conductor 102 is driven in the audible frequency band.
  • the coil conductor 102 is covered with the insulator 101 to form the coil-encapsulated insulating enclosure 104, and the coil-encapsulated insulating enclosure 104 is embedded inside the magnetic core core 105.
  • the heat generated in the conductor 102 is not dissipated to the outside but is trapped inside, which may cause a temperature rise.
  • the present invention has been made in view of such circumstances, and an object of the present invention is to provide a small and high-performance reactor having good heat dissipation and a cooling structure of the reactor capable of efficiently cooling the reactor. do.
  • the reactor according to the present invention has a coil conductor in which a conducting wire is wound so as to have a hollow portion, and a magnetic core core containing a magnetic material, and is magnetized by energization on the magnetic core core.
  • a reactor that forms a path, the coil conductor is covered with a non-magnetic material portion containing a first non-magnetic resin material as a main component, and the non-magnetic material portion has a high heat that promotes heat conduction. It contains a conductive filler, and a part of the non-magnetic material portion is exposed on the surface of the magnetic core core.
  • the non-magnetic material portion has a thermal conductivity of 1 W / m ⁇ K or more.
  • the thermal conductivity of the non-magnetic material portion becomes higher than 1 W / m ⁇ K, so that the heat generated by the coil conductor can be efficiently dissipated from the non-magnetic material portion exposed on the surface of the magnetic core core. can.
  • a high thermal conductive member having a higher thermal conductivity than the magnetic core is attached to the magnetic core, and at least one of the main surfaces of the high thermal conductive member is the non-magnetic material portion. It is preferable that it is in contact with.
  • the non-magnetic material portion contains the high thermal conductive filler and is in contact with the high thermal conductive member, so that the heat generated by the coil conductor can be dissipated more effectively.
  • the magnetic core core has a recess and the high thermal conductive member is joined to the recess.
  • a gap (gap) in the magnetic path in the magnetic core core (referred to as “core gap”) so that energy can be stored in the core gap.
  • the non-magnetic material portion covers the coil conductor and forms a core gap.
  • the core gap can take various forms.
  • the non-magnetic material portion has a flat resin portion that closes the central cavity formed by covering the coil conductor, and the flat resin portion forms the core gap. It is also preferable that the non-magnetic material portion has a ridge portion and the ridge portion forms the core gap.
  • the non-magnetic material portion is a molded body.
  • the conducting wire is formed of a flat wire.
  • the flat wire has a larger space factor than the round wire, so that a reactor having a larger inductance can be obtained.
  • the conducting wire is formed of a flat wire and the coil conductor is flatwise wound.
  • the magnetic core core contains a resin material.
  • the magnetic material is either a soft magnetic metal material or a ferrite material.
  • the cooling structure of the reactor according to the present invention is characterized in that the above-mentioned reactor is housed in a case and the non-magnetic material portion constituting the reactor is in contact with the case.
  • the non-magnetic material part comes into contact with the case, so that the reactor can be effectively cooled through the case.
  • the reactor is provided on the cooling plate.
  • the reactor described above is covered with an exterior resin portion formed of a second non-magnetic resin material, and the non-magnetic body portion constituting the reactor is the exterior resin. It is characterized by being in contact with the department.
  • the reactor can be cooled via the exterior resin portion, and the device can be miniaturized.
  • the reactor is provided on the cooling plate as described above, and the exterior resin portion is formed in a portion other than the portion where the reactor is in contact with the cooling plate.
  • the cooling structure of the reactor according to the present invention is the same for the first non-magnetic resin material and the second non-magnetic resin material constituting the non-magnetic material portion.
  • a reactor having a coil conductor in which a conducting wire is wound so as to have a hollow portion and a magnetic core containing a magnetic material, and forming a magnetic path in the magnetic core core by energization.
  • the coil conductor is coated with a non-magnetic material portion containing a first non-magnetic resin material as a main component, and the non-magnetic material portion contains a highly thermally conductive filler that promotes thermal conduction. Since a part of the non-magnetic material portion is exposed on the surface of the magnetic core core, it is possible to prevent heat generated from the coil conductor from being trapped inside the magnetic core core or the non-magnetic material portion. Since the high thermal conductivity filler contained in the non-magnetic material promotes thermal conduction, the heat generated from the coil conductor can be dissipated to the outside without being accumulated inside, and good heat dissipation can be achieved. Can be secured.
  • the reactor described above is housed in the case, and the non-magnetic material portion constituting the reactor is in contact with the case, so that the reactor is cooled through the case. Can be made to.
  • the reactor described above is covered with an exterior resin portion formed of a second non-magnetic resin material, and the non-magnetic body portion constituting the reactor is the exterior. Since it is in contact with the resin portion, the reactor can be cooled via the exterior resin portion, and the device can be miniaturized.
  • the coating process of coating the coil conductor with the non-magnetic material portion is performed by mold molding. Therefore, in the following description, this molded body is referred to as "coil mold molded body”.
  • FIG. 2 is a cross-sectional view taken along the line AA of FIG.
  • FIG. 2 is a cross-sectional view taken along the line BB of FIG.
  • FIG. 5 is a cross-sectional view taken along the line CC of FIG.
  • FIG. 5 is a cross-sectional view taken along the line DD of FIG.
  • FIG. 5 is sectional drawing which shows typically the modification of the 1st Embodiment. It is a perspective view which looked at the said modification from the bottom side.
  • FIG. 9 is an exploded perspective view of a main part of FIG. It is a perspective view which shows typically the coil molded body in the 2nd Embodiment of the reactor which concerns on this invention.
  • FIG. 11 is a cross-sectional view taken along the line EE of FIG. It is sectional drawing which shows typically the 2nd Embodiment of the reactor which concerns on this invention. It is a perspective view which shows typically the coil molded body in the 1st modification of 2nd Embodiment.
  • FIG. 14 is a cross-sectional view taken along the line FF of FIG. It is a perspective view which shows typically the 1st modification of the 2nd Embodiment of the reactor which concerns on this invention.
  • FIG. 17 is a cross-sectional view taken along the line GG of FIG.
  • FIG. 8 is a cross-sectional view taken along the line HU of FIG. It is a perspective view which shows typically the 2nd modification of the 2nd Embodiment of the reactor which concerns on this invention.
  • FIG. 20 is a cross-sectional view taken along the line II of FIG. It is a perspective view which shows typically the 3rd modification of the 2nd Embodiment. It is a perspective view which looked at the said 3rd modification from the bottom side. It is a perspective view which shows typically the 3rd modification of the 2nd Embodiment of the reactor which concerns on this invention. It is a perspective view which looked at the said 3rd modification from the bottom side.
  • FIG. 26 is a cross-sectional view taken along the line JJ in FIG. 26. It is a perspective view which shows typically the 1st modification of the cooling structure of the reactor.
  • FIG. 28 is a cross-sectional view taken along the line KK of FIG. 28. It is sectional drawing which shows typically the 2nd modification of the cooling structure of the reactor. It is sectional drawing which shows typically the 3rd modification of the cooling structure of the reactor. It is a main part exploded perspective view of the said 3rd modification. It is a perspective view which shows the 4th modification of the cooling structure of the reactor.
  • FIG. 33 is a cross-sectional view taken along the line LL of FIG. 33. It is sectional drawing of the coil component described in Patent Document 1.
  • FIG. 33 is a cross-sectional view taken along the line LL of FIG. 33. It is sectional drawing of the coil component described in Patent Document 1.
  • FIG. 33 is a cross-sectional view taken along the line LL of FIG. 33. It is sectional drawing of the
  • FIG. 1 is a perspective view showing an example of a coil conductor used in the reactor of the present invention.
  • the coil conductor 1 has a wound portion 4 in which a conducting wire 3 is spirally wound so as to have a hollow portion 2, and both ends are vertically erected to form terminal portions 5a and 5b. ..
  • the conductor 3 is formed of a flat flat wire.
  • the lead wire 3 has a core material formed of a metal material such as Cu, Al or alloys thereof, and the core material is coated with an enamel material such as polyamide-imide.
  • the coil conductor 1 is a flatwise winding in which a flat flat wire is wound in a spiral shape by bending the short side (thickness direction) of the cross section.
  • the conductor 3 By forming the conductor 3 as a flat wire in this way, the space factor can be increased as compared with the round wire, so that a reactor having a large inductance can be obtained.
  • the thermal conductivity of the reactor in the vertical direction is high, so that heat can be effectively dissipated to the bottom surface side of the reactor, and the reactor can be placed on the cooling plate. A better cooling effect can be obtained when installed.
  • edgewise winding in which the long side (width direction) of the cross section of the flat wire is bent and flatwise winding described above are known. Is not particularly limited.
  • the long side (width direction) of the cross section is bent with respect to the flat wire, so that the reactor has good thermal conductivity in the horizontal direction, but there are many heat transfer interfaces in the vertical direction. Thermal conductivity may decrease in the vertical direction.
  • the coil conductor 1 is more preferably flatwise wound with good thermal conductivity in the vertical direction as in the present embodiment. preferable.
  • FIG. 2 is a perspective view schematically showing a first embodiment of the reactor according to the present invention.
  • FIG. 3 is a cross-sectional view taken along the line AA of FIG. 2
  • FIG. 4 is a cross-sectional view taken along the line BB of FIG.
  • the coil conductor 1 is covered with the non-magnetic material portion 6 by molding, thereby forming the coil molded body 7. Then, in this reactor, the coil molded body 7 is further embedded in a magnetic core 8 containing a magnetic material by molding.
  • the magnetic core 8 has a three-dimensional shape having a pair of upper and lower main surfaces 9a and 9b, a pair of end surface portions 10a and 10b, and a pair of side surface portions 11a and 11b, thereby forming the appearance of a reactor. A part of the non-magnetic material portion 6 is exposed on the end face portions 10a and 10b (surface) of the magnetic core core 8.
  • a soft magnetic metal material or a ferrite material can be used as the magnetic material powder contained in the magnetic core core 8.
  • the soft magnetic metal material is not particularly limited, and for example, Fe—Si alloys, Fe—Si—Cr alloys, Fe—Al alloys, Fe—Ni alloys, Fe—Co alloys, etc.
  • Various crystalline alloy powder materials, an amorphous material containing Fe as a main component and having excellent soft magnetic properties, or a nanocrystalline metal material in which an amorphous phase and a nanocrystalline phase are mixed can be used.
  • this soft magnetic metal material it is preferable to form a coating layer made of an insulating material such as a phosphate or a silicone resin on the surface of the metal powder from the viewpoint of ensuring the insulating property.
  • the ferrite material is not particularly limited, and Fe 2 O 3 such as Ni-based, Cu-Zn-based, Ni-Zn-based, Mn-Zn-based, and Ni-Cu-Zn-based is used as a main component.
  • Fe 2 O 3 such as Ni-based, Cu-Zn-based, Ni-Zn-based, Mn-Zn-based, and Ni-Cu-Zn-based is used as a main component.
  • Various ferrite materials can be used.
  • the magnetic core core 8 usually contains a resin material such as an epoxy resin or a silicone resin as a binder in a volume ratio of 40 vol% or less.
  • FIG. 5 is a perspective view of the coil molded body 7. 6 is a cross-sectional view taken along the line CC of FIG. 5, and FIG. 7 is a cross-sectional view taken along the line DD of FIG.
  • the winding portion 4 of the coil conductor 1 shown in FIG. 1 is covered with the non-magnetic material portion 6 to form the central cavity portion 12, and the terminal portions 5a and 5b are non-magnetic materials. It is erected from one main surface of the part 6.
  • the thickness of the non-magnetic material portion 6 is not particularly limited, and is adjusted to, for example, about 0.1 to 3 mm.
  • the non-magnetic material portion 6 is formed mainly of the first non-magnetic system material and contains a highly thermally conductive filler that promotes thermal conduction.
  • the first non-magnetic resin material is not particularly limited as long as it belongs to the category, and for example, an epoxy resin, a silicone resin, a polyphenylene sulfide resin, or the like can be used.
  • the high thermal conductivity filler is not particularly limited as long as it is a material that promotes thermal conductivity, that is, a material having a higher thermal conductivity than the magnetic core core 8, and for example, alumina or the like can be used.
  • the content of the high thermal conductive filler in the non-magnetic material portion 6 is not particularly limited, and is set to, for example, 50 to 80 vol% in terms of volume ratio. That is, the non-magnetic material portion 6 has a thermal conductivity of preferably 1 W / m ⁇ K or more, more preferably 1 W / m ⁇ K or more, by adjusting the type and content of the first non-magnetic resin material and the highly thermally conductive filler. It is set to 5 W / m ⁇ K or more, which promotes heat conduction and ensures good heat dissipation.
  • this reactor is molded by the injection molding method and integrally formed.
  • the method for producing this reactor will be described in detail.
  • a coil conductor 1 in which the conducting wire 3 as shown in FIG. 1 described above is spirally wound is produced.
  • an upper mold and a lower mold for producing the coil mold molded body are prepared.
  • the upper mold is set and the mold is fastened.
  • a mixture of the first non-magnetic resin material and the high thermal conductive filler is supplied to the cavity and heated to cure the mixture, and the coil conductor 1 is coated with the mixture. That is, the coil conductor 1 is covered with the non-magnetic material portion 6 made of the mixture, whereby the coil molded body 7 is produced.
  • an upper mold and a lower mold for producing a core mold molded body for molding the coil mold molded body 7 with the core material are prepared. Then, after the coil mold molded body 7 is arranged at a predetermined position of the lower mold so that the non-magnetic body portion 6 is exposed to the end face portions 10a and 10b of the magnetic core core 8 after molding, the upper mold is set and the mold is fastened. Then, the core material is supplied to the cavity and heated to cure the core material, thereby molding, and the reactor of the present embodiment in which the coil molded body 7 is embedded in the magnetic core core 8 is produced.
  • the reactor When the coil conductor 1 is energized, the reactor thus formed passes through a magnetic path so that the magnetic flux passes through the central cavity 12 of the non-magnetic material portion 6 and the magnetic core core 8 located on the outer peripheral portion.
  • the reactor has a coil conductor 1 in which a conducting wire 3 is wound so as to have a hollow portion 2, and a magnetic core core 8 containing a magnetic material.
  • the coil conductor 1 is a first non-magnetic system.
  • the non-magnetic material portion 6 is covered with a non-magnetic material portion 6 containing a resin material as a main component, and the non-magnetic material portion 6 contains a highly thermally conductive filler that promotes thermal conductivity, and a part of the non-magnetic material portion 6 is Since it is exposed on the end face portions 10a and 10b of the magnetic core core 8, it is possible to prevent the heat generated from the coil conductor 1 during energization from being trapped inside the magnetic core core 8 and the non-magnetic material portion 6. Then, the heat generated in the coil conductor 1 can be efficiently dissipated to the outside through the non-magnetic material portion 6 containing the highly thermally conductive filler, and good heat dissipation can be ensured.
  • FIG. 8 is a cross-sectional view showing a modified example of the first embodiment
  • FIG. 9 is a perspective view of this modified example as viewed from the bottom surface side.
  • a pair of trapezoidal high thermal conductive members 19a and 19b having a higher thermal conductivity than the magnetic core 18 are attached to the bottom surface of the non-magnetic material portion 6, thereby causing the high thermal conductive members 19a and 19b. Is configured to be in contact with the non-magnetic material portion 6.
  • FIG. 10 is an exploded perspective view of a main part of this modified example.
  • a pair of recesses 20a and 20b are formed on the bottom surface of the magnetic core core 18 so that a part of the non-magnetic body portion 6 is exposed on the surface of the magnetic core core 18.
  • the recesses 20a and 20b are cut out in a trapezoidal shape so that the high thermal conductive members 19a and 19b can be joined, and the high thermal conductive members 19a and 19b are attached to the recesses 20a and 20b with an adhesive or the like. ..
  • the high thermal conductive members 19a and 19b are not particularly limited as long as they have a higher thermal conductivity than the magnetic core core 18, and are formed of a material mainly composed of a metal material such as aluminum or copper. There is.
  • the high thermal conductive members 19a and 19b having higher thermal conductivity than the magnetic core 18 are attached to the magnetic core 18, and the upper surfaces of the high thermal conductive members 19a and 19b are in contact with the non-magnetic material portion 6. Therefore, the heat generated by the coil conductor 1 can be effectively dissipated to the outside through the high thermal conductive members 19a and 19b, and in combination with the heat dissipation of the high thermal conductive non-magnetic material portion 6 itself, the heat is further increased. It is possible to improve the heat dissipation of the.
  • the heat conductive members 19a and 19b are formed in a trapezoidal shape in the above modification, the heat conductive members 19a and 19b are not limited to the trapezoidal shape and may be rectangular, for example. Further, in this modification, the upper surfaces of the high thermal conductive members 19a and 19b are in contact with the non-magnetic material portion 6, but the contact surface with the non-magnetic material portion 6 is not limited to the upper surface, and at least one. By bringing the main surface into contact with the non-magnetic material portion 6, it is possible to improve heat dissipation.
  • FIG. 11 is a perspective view of the coil molded body according to the second embodiment
  • FIG. 12 is a cross-sectional view taken along the line EE of FIG.
  • the coil conductor 1 is covered so that the non-magnetic material portion 6 has the central cavity portion 12, but in the second embodiment, the non-magnetic material portion 21 is covered.
  • the coil conductor 1 is covered and the central cavity is closed to form the flat resin portion 22, and the flat resin portion 22 forms a core gap.
  • a core gap having a gap in the magnetic path in the magnetic core has been formed so that magnetic saturation is unlikely to occur even if a large current is passed through the coil conductor 1.
  • the magnetic core core was manufactured by dividing it into a plurality of blocks, and for example, a thin ceramic substrate was interposed between the plurality of blocks to form a core gap.
  • the flat resin portion 22 which becomes a core gap in the mixture is formed.
  • the non-magnetic part 21 is produced so as to be formed, and then the non-magnetic part 21 is covered with a core material, thereby forming a core gap.
  • the core gap can be formed without requiring a complicated manufacturing process of dividing into a plurality of blocks and interposing a ceramic substrate or the like between the blocks as in the conventional case. We are trying to improve productivity.
  • molding is performed using an upper mold and a lower mold that form a core gap, and the first non-magnetic resin material and the high thermal conductive filler are combined.
  • the central cavity portion (see FIG. 5 and the like) is closed with the mixture to form a flat resin portion 22 serving as a core gap, whereby the flat surface as shown in FIGS. 11 and 12 is formed.
  • the non-magnetic material portion 21 including the resin portion 22 and the coil conductor 1 are integrally formed to obtain a coil molded body 23.
  • the core material is used for molding, whereby a reactor having a core gap can be produced.
  • FIG. 13 is a cross-sectional view schematically showing a second embodiment of the reactor according to the present invention, in which the coil mold molded body 23 is embedded in the magnetic core core 50.
  • the coil-molded body 23 since the coil-molded body 23 has the flat resin portion 22, the coil-molded body 23 is molded so as to be embedded in the magnetic core core 50, so that the core gap at the interval t1 is formed in the flat resin portion 22. It is formed, thereby obtaining a reactor in which the magnetic core core 50 is divided into two parts.
  • the non-magnetic material portion 21 is exposed on the end face portions 10a and 10b of the magnetic core core 50, so that heat dissipation can be ensured. Further, since the flat resin portion 22 forms a core gap having an interval t1, energy can be stored in the core gap, and therefore magnetic saturation is less likely to occur even when a large current is passed, resulting in a small size and high performance. You can get a reactor.
  • the flat resin portion 22 is formed at the same time as the coating treatment of the coil conductor 1 by molding, and since the flat resin portion 22 has a core gap as described above, the flat resin portion 22 is divided into a plurality of blocks as in the conventional case and is ceramic. The complicated manufacturing process of interposing a substrate or the like between blocks becomes unnecessary, and productivity can be improved.
  • FIG. 14 is a perspective view of the coil molded body of the first modified example according to the second embodiment
  • FIG. 15 is a cross-sectional view taken along the line FF of FIG.
  • the non-magnetic material portion 24 has the central cavity portion 12 as in the first embodiment, while the non-magnetic material portion 24 has a pair of main surfaces 25a on one main surface 25a.
  • the ridges 26 and 26b are formed so as to be parallel to each other, and a pair of ridges 26c and 26d are formed on the other main surface 25b so as to face the convex portions 26a and 26b.
  • the non-magnetic material portion 24 including the strip portions 26a to 26d is molded so as to cover the coil conductor 1, whereby the coil mold molded body 27 is formed.
  • FIG. 16 is a perspective view of a reactor according to a first modification provided with the coil molded body 27, and FIG. 17 is a cross-sectional view taken along the line GG of FIG.
  • this reactor is integrally formed by molding so that the coil molded body 27 is embedded in the magnetic core core 28.
  • the ridges 26a to 26d are exposed on both main surfaces of the magnetic core 28, and the ridges 26a to 26d form a core gap with an interval t2, and the core gap divides the magnetic core 28 into three parts. Has been done.
  • the non-magnetic material portion 24 is exposed on the end face portions 29a and 29b of the magnetic core core 28, so that heat dissipation can be ensured.
  • the non-magnetic material portion 24 covers the coil conductor 1 and has ridge portions 26a to 26d, and as described above, the ridge portions 26a to 26d form a core gap with an interval t2. Therefore, as in the second embodiment, energy can be stored in the core gap, a small and high-performance reactor can be obtained, and the reactor can be manufactured without requiring a complicated manufacturing process. , Productivity can be improved.
  • FIG. 18 is a perspective view of a coil molded body of a second modified example according to the second embodiment
  • FIG. 19 is a cross-sectional view taken along the line OH of FIG.
  • the non-magnetic material portion 24 has a central cavity portion 12 as in the first modification (FIG. 14), while the side surface portions 30a and 30b have convex portions in the horizontal direction, respectively. 31a and 31b are formed. Then, the non-magnetic material portion 33 including the convex portions 31a and 31b is molded so as to cover the coil conductor 1, whereby the coil molded body 32 is formed.
  • FIG. 20 is a perspective view of a reactor according to a second modification provided with the coil molded body 32
  • FIG. 21 is a cross-sectional view taken along the line II of FIG.
  • This reactor is integrally formed by molding so that the coil molded body 32 is embedded in the magnetic core core 34, and a core gap with an interval t3 is formed by the ridges 31a and 31b.
  • the non-magnetic material portion 33 is exposed on the end face portions 57a and 57b of the magnetic core core 34 to ensure heat dissipation. Further, in the second modification, the non-magnetic material portion 33 covers the coil conductor 1 and has the ridge portions 31a and 31b, and as shown in FIG. 21, the ridge portions 31a and 31b are formed. A core gap with an interval of t3 is formed. Therefore, as in the second embodiment, energy can be stored in the core gap, a small and high-performance reactor can be obtained, and the reactor can be manufactured without requiring a complicated manufacturing process. , Productivity can be improved.
  • FIG. 22 is a perspective view of the coil molded body of the third modified example according to the second embodiment
  • FIG. 23 is a perspective view seen from the bottom surface side.
  • the non-magnetic body portion 35 has a central cavity portion 12 as in the first and second modifications (FIGS. 14 and 18), while one main surface 58a has one.
  • a pair of ridges 36a and 36b are formed in parallel from the end face portion 59a of the ridge to the other end face portion 59b, and both end face portions 59a face the ridges 36a and 36b on the other main surface 58b.
  • the ridges 36c and 36d that do not extend to 59b are formed.
  • the non-magnetic material portion 35 including these convex portions 36a to 36d is molded so as to cover the coil conductor 1, whereby the coil molded body 60 is formed.
  • FIG. 24 is a perspective view of the reactor according to the third modified example provided with the coil molded body 60
  • FIG. 25 is a perspective view seen from the bottom surface side.
  • the non-magnetic material portion 35 is exposed on the end face portions 39a and 39b of the magnetic core core 38, and the ridge portions 36a to 36d are exposed on the surface of the magnetic core core 38, and the ridge portions 36a to 36d.
  • a core gap with an interval of t4 is formed.
  • a recess similar to that of the modification of the first embodiment is formed on the bottom surface of the magnetic core core 38 (see FIG. 10), and the trapezoidal high heat conductive member is formed in the recess. 37a and 37b are attached.
  • the non-magnetic material portion 35 is exposed on the end face portions 39a and 39b of the magnetic core core 38, which is combined with the heat dissipation action of the high heat conductive members 37a and 37b.
  • the non-magnetic material portion 35 covers the coil conductor 1 and has ridge portions 36a to 36d, and the ridge portions 36a to 36d form a core gap with an interval t4. is doing. Therefore, as in the second embodiment, energy can be stored in the core gap, a small and high-performance reactor can be obtained, and the reactor can be manufactured without requiring a complicated manufacturing process. , Productivity can be improved.
  • FIG. 26 is a perspective view showing an embodiment of a reactor cooling structure according to the present invention
  • FIG. 27 is a cross-sectional view taken along the line JJ of FIG. 26.
  • the reactor 40 (see FIGS. 2 to 4) shown in the first embodiment is housed in the case 42 via the adhesive 41.
  • the case 42 is made of a material containing a metal material such as aluminum as a main component, and has end face portions 43a and 43b, side surface portions 44a and 44b, and a bottom surface portion 45. Since the non-magnetic material portion 6 is in contact with the case 42 via the adhesive 41, the heat propagated from the coil conductor 1 to the non-magnetic material portion 6 is cooled by the case 42. ..
  • the adhesive 41 one having a high thermal conductivity can be preferably used, and by using the adhesive 41 having a high thermal conductivity in this way, the reactor can be cooled more effectively. Further, it is also possible to use an adhesive having a low thermal conductivity, and in that case, it is preferable to reduce the coating thickness of the adhesive. Further, if the reactor 40 can be accommodated in close contact with the case 42, the adhesive can be omitted.
  • FIG. 28 is a perspective view showing a first modification of the cooling structure of the reactor
  • FIG. 29 is a cross-sectional view taken along the line KK of FIG. 28.
  • the reactor 40 is housed in the case 42, but in the first modification, the reactor 40 is covered with the exterior resin portion 46 instead of the case 42.
  • one main surface 9a, end surface portions 10a and 10b, and side surface portions 11a and 11b (see FIG. 2) of the reactor 40 are covered with an exterior resin portion 46 made of a second non-magnetic resin material. ..
  • the non-magnetic material portion 6 since the non-magnetic material portion 6 is in contact with the exterior resin portion 46, the heat propagated from the coil conductor 1 to the non-magnetic material portion 6 is transferred to the non-magnetic material portion 6 and the exterior resin portion 6. Heat is transferred to the contact surface with the portion 46 and cooled by the exterior resin portion 46. Moreover, since the reactor 40 is covered with the exterior resin portion 46, the layer can be made thinner than when it is housed in the case 42, so that the size and weight can be reduced.
  • the second non-magnetic resin material is not particularly limited as long as it belongs to the category, and for example, an epoxy resin, a silicone resin, a polyphenylene sulfide resin, etc. of the same type as the first non-magnetic resin material can be used. It can be used, and it is also preferable to contain a highly thermally conductive filler.
  • FIG. 30 is a cross-sectional view showing a second modification of the cooling structure of the reactor.
  • the reactor 47 (see FIG. 8) to which the high thermal conductive members 19a and 19b are attached is covered with the exterior resin portion 46 as in the first modification.
  • the heat propagated from the coil conductor 1 to the non-magnetic material portion 6 is generated. It is propagated to the contact surface between the non-magnetic material portion 6 and the exterior resin portion 46 and the high thermal conductive members 19a and 19b, dissipated to the outside through the high thermal conductive members 19a and 19b, cooled by the exterior resin portion 46, and is compact. -It is possible to realize a reactor cooling structure that can reduce weight.
  • FIG. 31 is a cross-sectional view showing a third modification of the cooling structure of the reactor.
  • the reactor 47 coated with the exterior resin portion 48 is provided on the cooling plate 49, and a part of the bottom surface of the magnetic core core 18 is formed on the cooling plate 49. I'm in contact.
  • FIG. 32 is an exploded perspective view of a main part of this third modification.
  • the magnetic core core 18 is provided with a recess similar to that in FIG.
  • the high thermal conductive members 19a and 19b are attached to the predetermined positions of the flat plate-shaped cooling plate 49, they are attached to the recesses of the magnetic core core 18, and then molding is performed on the high thermal conductive members 19a and 19b to form the exterior resin portion 48. Is forming.
  • the non-magnetic material portion 6 and the high thermal conductive members 19a and 19b are in contact with the exterior resin portion 48, and a part of the magnetic core core 18 and the high thermal conductive members 19a and 19b are in contact with the cooling plate 49. Therefore, it is propagated to the contact surface between the non-magnetic material portion 6 and the exterior resin portion 48 and the high heat conductive members 19a and 19b, cooled by the exterior resin portion 48, and the coil conductor 1 is provided by the heat conductive members 19a and 19b. The heat generated from the cooling plate 49 is propagated to the cooling plate 49 to be cooled.
  • the magnetic core 18 is in contact with the cooling plate 49, the heat diffused from the non-magnetic material portion 6 to the magnetic core 18 can be cooled by the cooling plate 49, which makes it possible to reduce the size and weight, which is better.
  • a cooling structure for the reactor can be realized.
  • FIG. 33 is a perspective view showing a fourth modification of the cooling structure of the reactor
  • FIG. 34 is a cross-sectional view taken along the line LL of FIG. 33.
  • the reactor 47 coated with the exterior resin portion 46 shown in the second modification is housed in the housing 51, and the housing 51 is on the cooling plate 53 having a large number of water supply ports 52. It is fixed to the door via a fastener 54 such as a screw.
  • the present invention is not limited to the above embodiment, and various modifications can be made without departing from the gist.
  • the cooling structure of the reactor has been described in detail when the reactor of the first embodiment is applied, but the reactor according to the second embodiment having a core gap has been described in detail. Needless to say, can be applied in the same way.
  • the cooling structure of the reactor the case where the reactor is covered with the exterior resin portion has been described in the second to fourth modified examples, but it goes without saying that the same applies to the case where the reactor is housed in the case.
  • the molding is performed by injection molding, but the molding processing method is not particularly limited, and the molding may be performed by transfer molding, sheet press molding, or the like.
  • the first non-magnetic resin material is used as a main component, and a mixture containing a highly thermally conductive filler is used for molding to form a non-magnetic material portion.
  • a component other than the first non-magnetic resin material and the high thermal conductive filler may be contained as long as it does not affect the material.
  • the coil conductor winds the conducting wire in a spiral shape, but it may be wound in a spiral shape.
  • the conducting wire is formed of a covered flat wire, but a U-shaped foil-shaped conductor or a round wire may be used.
  • foil-like conductors after winding the foil-like conductors so that they overlap each other, the corners of the overlapping foil-like conductors are crimped together to be integrated, or each foil-like conductor is connected via vias.
  • a tubular coil conductor can be manufactured by laminating and electrically connecting and integrating the foil-shaped conductors with each other.
  • the use of a round wire having a circular cross-sectional shape does not affect the solution of the problem of the present invention.

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  • Coils Of Transformers For General Uses (AREA)
PCT/JP2020/048872 2020-01-30 2020-12-25 リアクトル、及びリアクトルの冷却構造 WO2021153135A1 (ja)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2023102370A (ja) * 2022-01-12 2023-07-25 株式会社村田製作所 リアクトル

Citations (4)

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Publication number Priority date Publication date Assignee Title
JP2013093549A (ja) * 2011-10-06 2013-05-16 Sumitomo Electric Ind Ltd リアクトル、リアクトル用コイル部品、コンバータ、及び電力変換装置
JP2015076478A (ja) * 2013-10-08 2015-04-20 Ｎｅｃトーキン株式会社 リアクトル
JP2015225899A (ja) * 2014-05-26 2015-12-14 トヨタ自動車株式会社 リアクトル
JP2017228741A (ja) * 2016-06-24 2017-12-28 株式会社トーキン コイル部品

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013093549A (ja) * 2011-10-06 2013-05-16 Sumitomo Electric Ind Ltd リアクトル、リアクトル用コイル部品、コンバータ、及び電力変換装置
JP2015076478A (ja) * 2013-10-08 2015-04-20 Ｎｅｃトーキン株式会社 リアクトル
JP2015225899A (ja) * 2014-05-26 2015-12-14 トヨタ自動車株式会社 リアクトル
JP2017228741A (ja) * 2016-06-24 2017-12-28 株式会社トーキン コイル部品

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2023102370A (ja) * 2022-01-12 2023-07-25 株式会社村田製作所 リアクトル

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