WO2021177190A1 - Réacteur, convertisseur et dispositif de conversion de puissance - Google Patents

Réacteur, convertisseur et dispositif de conversion de puissance Download PDF

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Publication number
WO2021177190A1
WO2021177190A1 PCT/JP2021/007537 JP2021007537W WO2021177190A1 WO 2021177190 A1 WO2021177190 A1 WO 2021177190A1 JP 2021007537 W JP2021007537 W JP 2021007537W WO 2021177190 A1 WO2021177190 A1 WO 2021177190A1
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Prior art keywords
core
length
core portion
piece
winding
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PCT/JP2021/007537
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English (en)
Japanese (ja)
Inventor
和宏 稲葉
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株式会社オートネットワーク技術研究所
住友電装株式会社
住友電気工業株式会社
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Application filed by 株式会社オートネットワーク技術研究所, 住友電装株式会社, 住友電気工業株式会社 filed Critical 株式会社オートネットワーク技術研究所
Publication of WO2021177190A1 publication Critical patent/WO2021177190A1/fr

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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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
    • H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
    • H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only

Definitions

  • the present disclosure relates to reactors, converters, and power converters.
  • This application claims priority based on Japanese Patent Application No. 2020-035395 of the Japanese application dated March 02, 2020, and incorporates all the contents described in the Japanese application.
  • the reactor of Patent Document 1 includes a coil, a magnetic core, a case, and a cooling tube.
  • the coil is formed by spirally winding a winding.
  • the magnetic core has an inner core portion and an outer core portion.
  • the inner core portion is arranged inside the coil.
  • the outer core portion covers both end surfaces of the inner core portion and both end surfaces and the outer peripheral surface of the coil.
  • the inner core portion is composed of a powder compact, and the outer core portion is composed of a composite material molded body.
  • the case houses a combination of a coil and a magnetic core inside. This case functions as a magnetic shield and prevents magnetic flux from leaking to the outside of the case.
  • the union can be stored in the case by arranging the coil and the inner core portion in the case, filling the case with the raw material of the composite material, and curing the composite material.
  • Refrigerant flows inside the cooling pipe.
  • the cooling pipe is spirally wound in the circumferential direction of the case so as to be in contact with the outer peripheral surface of the case.
  • the reactor according to the present disclosure is a reactor including a coil and a magnetic core.
  • the coil has a tubular winding portion, and the magnetic core has a first core portion and a second core portion. It is a combined assembly, the first core portion has a first end core piece facing one end face of the winding portion, and the second core portion is on the other end face of the winding portion. It has a second end core piece facing, the saturation magnetic flux density of the second core portion is larger than the saturation magnetic flux density of the first core portion, and the length L3s of the second end core piece is the first end core piece.
  • the length L3s of the second end core piece is shorter than the length L3f of the above, and the length L3s of the second end core piece is the length along the axial direction of the winding portion in the second end core piece, and the length L3f of the first end core piece is. , The length of the first end core piece along the axial direction of the winding portion.
  • the converter according to the present disclosure includes the reactor of the present disclosure.
  • the power conversion device includes the converter of the present disclosure.
  • FIG. 1 is a perspective view showing an outline of the entire reactor according to the first embodiment.
  • FIG. 2 is a perspective view showing an outline of a state in which the reactor according to the first embodiment is disassembled.
  • FIG. 3 is a top view showing an outline of the entire reactor according to the first embodiment.
  • FIG. 4 is a top view showing an outline of the entire reactor according to the second embodiment.
  • FIG. 5 is a top view showing an outline of the entire reactor according to the third embodiment.
  • FIG. 6 is a top view showing an outline of the entire reactor according to the fourth embodiment.
  • FIG. 7 is a perspective view showing an outline of the entire reactor according to the fifth embodiment.
  • FIG. 8 is a perspective view showing an outline of a state in which the reactor according to the fifth embodiment is disassembled.
  • FIG. 8 is a perspective view showing an outline of a state in which the reactor according to the fifth embodiment is disassembled.
  • FIG. 9 is a top view showing an outline of the entire reactor according to the fifth embodiment.
  • FIG. 10 is a top view showing an outline of the entire reactor according to the sixth embodiment.
  • FIG. 11 is a top view showing an outline of the entire reactor according to the seventh embodiment.
  • FIG. 12 is a top view showing an outline of the entire reactor according to the eighth embodiment.
  • FIG. 13 is a configuration diagram schematically showing a power supply system of a hybrid vehicle.
  • FIG. 14 is a circuit diagram showing an outline of an example of a power conversion device including a converter.
  • the inductance can be easily adjusted by forming the inner core portion and the outer core portion with different materials.
  • the above-mentioned union since the coil and the inner core portion are embedded in the outer core portion, it is difficult to adjust the heat dissipation. This is because the surface of the union is substantially composed of only the constituent materials of the outer core portion. Moreover, the union has low heat dissipation. This is because the outer core portion is made of a composite material and has a relatively low thermal conductivity. Therefore, the reactor enhances the heat dissipation performance of the union by storing the union in a case around which the cooling pipe is wound. However, the above reactor becomes large because the cooling pipe is wound around the case.
  • One of the purposes of the present disclosure is to provide a reactor in which the inductance can be easily adjusted without increasing the size.
  • Another object of the present disclosure is to provide a converter having the above reactor.
  • one of the other purposes of the present disclosure is to provide a power conversion device including the above converter.
  • the reactor according to the present disclosure can easily adjust the inductance without increasing the size.
  • the converter according to the present disclosure and the power conversion device according to the present disclosure are excellent in heat dissipation without increasing the size.
  • the reactor according to one embodiment of the present disclosure is a reactor including a coil and a magnetic core, the coil has a tubular winding portion, and the magnetic core has a first core portion. It is an assembly in which the second core portion is combined, the first core portion has a first end core piece facing one end surface of the winding portion, and the second core portion is the winding portion.
  • the saturation magnetic flux density of the second core portion is larger than the saturation magnetic flux density of the first core portion
  • the length L3s of the second end core piece is The length L3s of the second end core piece is shorter than the length L3f of the first end core piece, and the length L3s of the second end core piece is the length along the axial direction of the winding portion in the second end core piece.
  • the length L3f of the piece is the length along the axial direction of the winding portion in the first end core piece.
  • the above reactor is easy to adjust the inductance without increasing the size.
  • the length L3s of the second end core piece provided in the second core portion having a large saturation magnetic flux density is shorter than the length L3f of the first end core piece provided in the first core portion having a small saturation magnetic flux density. This is because the length of the wound portion along the axial direction can be shortened and the size can be reduced as compared with a reactor having the same saturation magnetic flux density of the first core portion and the second core portion.
  • the saturation magnetic flux density of the second core portion having the second end core piece is the first end core. This is because it is easy to reduce the variation between the magnetic flux density of the second core portion and the magnetic flux density of the first core portion because it is larger than the saturation magnetic flux density of the first core portion having the piece.
  • the above-mentioned reactor is easier to adjust the heat dissipation than the above-mentioned conventional reactor.
  • the magnetic core of the conventional reactor is formed by embedding a core portion having a relatively high thermal conductivity in a core portion having a relatively low thermal conductivity. That is, the surface of this magnetic core is equivalent to being composed of a single material.
  • the saturation magnetic flux densities of the first core portion and the second core portion constituting the magnetic core are different. That is, in the reactor, the first core portion and the second core portion can be composed of molded bodies made of different materials. Therefore, in the reactor, the surface of the magnetic core can be made of a different material.
  • the above-mentioned reactor is easier to improve heat dissipation than the above-mentioned conventional reactor.
  • the surface of the magnetic core is composed only of a core portion having a relatively low thermal conductivity as described above.
  • the reactor can include a surface of the magnetic core made of a material having excellent heat dissipation because the surface of the magnetic core can be made of a different material as described above.
  • the above reactor can be suitably used for a reactor that is cooled by a cooling member having a biased cooling performance.
  • the core portion having high heat dissipation performance is arranged on the side where the cooling performance of the cooling member is low, and the core portion having low heat dissipation performance is arranged on the side where the cooling performance of the cooling member is high.
  • the first core portion and the second core portion are cooled evenly, and the maximum temperature of the magnetic core is reduced. Since the maximum temperature of the magnetic core is reduced in this way, the reactor has a low loss.
  • the above-mentioned reactor is easy to adjust the heat dissipation property and easily improve the heat dissipation property as described above, it is not necessary to provide a cooling pipe like the above-mentioned conventional reactor. From this point as well, it is difficult for the above reactor to become large.
  • the above-mentioned reactor is easier to manufacture than the above-mentioned conventional reactor.
  • the above-mentioned conventional reactor is manufactured by filling a braid in which a coil and a middle core portion are combined with a raw material of a composite material and curing the composite material. At that time, it was necessary to sufficiently spread the composite material on the outer periphery of the above-mentioned braid, and it was difficult to produce the side core portion.
  • the first core portion and the second core portion are easy to manufacture because the inside and outside of the coil and the inside and outside of the other core portions are not filled with the composite material.
  • the relative magnetic permeability of the second core portion is larger than the relative magnetic permeability of the first core portion.
  • the reactor adjusts the inductance between the first core portion and the second core portion without passing through a large gap portion between the first core portion and the second core portion by satisfying the magnitude relationship of the relative magnetic permeability. Easy to do. Since the reactor does not have to pass through a large gap portion between the first core portion and the second core portion in this way, the leakage flux penetrates into the winding portion and the eddy current loss generated in the winding portion occurs. Is easy to reduce.
  • the above-mentioned reactor is easier to suppress the leakage flux to the outside without increasing the size as compared with the above-mentioned conventional reactor.
  • the conventional reactor described above is enlarged by providing a case to prevent magnetic flux from leaking to the outside of the reactor.
  • the relative magnetic permeability of the second core portion having the second end core piece is larger than the relative magnetic permeability of the first core portion having the first end core piece, so that the length of the second end core piece is larger than that of the first core portion. Even if L3s is shorter than the length L3f of the first end core piece, it is easy to suppress leakage of magnetic flux to the outside. Therefore, the reactor suppresses problems such as affecting peripheral devices due to the leaked magnetic flux.
  • the relative magnetic permeability of the first core portion is 5 or more and 50 or less.
  • the above reactor makes it easy to adjust the inductance.
  • the relative magnetic permeability of the second core portion is 50 or more and 500 or less.
  • the above reactor makes it easy to adjust the inductance.
  • a mold resin portion covering at least a part of the magnetic core may be provided.
  • the above reactor can protect the magnetic core from the external environment.
  • the length L3s of the second end core piece is ⁇ the length L3f ⁇ of the first end core piece (saturation magnetic flux density Bf of the first core part / the second core part. Saturation magnetic flux density Bs) ⁇ or higher.
  • the above reactor can easily reduce the variation between the magnetic flux density of the second core portion and the magnetic flux density of the first core portion while reducing the size.
  • the first core portion is composed of a molded body of a composite material in which soft magnetic powder is dispersed in a resin
  • the second core portion is a raw material powder containing soft magnetic powder. It can be mentioned that it is composed of a powder compact.
  • the first core portion is composed of a molded body of a composite material
  • the second core portion is composed of a dust compact, so that there is a large gap between the first core portion and the second core portion.
  • the second core portion is composed of a powder compact having a relatively high thermal conductivity, so that the heat dissipation property can be easily improved.
  • the number of the winding portions is two, the two winding portions are arranged in parallel so that the axial directions are parallel, and the magnetic core is formed.
  • the first end core piece facing both of the two end faces of the winding portion, the second end core piece facing both of the other end faces of the two winding portions, and one of the windings.
  • first middle core portion having a portion arranged inside the winding portion and a second middle core portion having a portion arranged inside the other winding portion, and the first core portion and the said The second core portion is combined in the axial direction of the winding portion, and the first core portion is selected from the group consisting of at least a part of the first middle core portion and at least a part of the second middle core portion. It is mentioned to have at least one to be done.
  • the above reactor makes it easy to adjust the inductance and heat dissipation. Further, since the reactor can be constructed by combining the first core portion and the second core portion with respect to the winding portion along the axial direction of the winding portion, the reactor is excellent in manufacturing workability.
  • the second core portion has at least one selected from the group consisting of the remaining portion of the first middle core portion and the remaining portion of the second middle core portion.
  • the remaining length L11s of the first middle core portion and the remaining length L12s of the second middle core portion are not more than twice the length L3s of the second end core piece, and the remaining portion of the first middle core portion.
  • the length L11s of is the length along the axial direction of the winding portion in the remaining portion of the first middle core portion
  • the length L12s of the remaining portion of the second middle core portion is the remaining length of the second middle core portion. It can be mentioned that the length is along the axial direction of the winding portion.
  • the compaction compact is formed by compression molding the raw material powder.
  • the pressurizing direction at the time of molding depends on the shape and size of the powder compact, but may be a direction along the axial direction of each middle core piece.
  • the length L11s and the length L12s are twice or less the length L3s, it is easy to reduce the variation in the pressure acting on each core piece at the time of molding the second core portion. Therefore, it is easy to manufacture the second core portion having a small variation in density.
  • the second core portion has at least one selected from the group consisting of the remaining portion of the first middle core portion and the remaining portion of the second middle core portion.
  • the remaining length L11s of the first middle core portion and the remaining length L12s of the second middle core portion are more than twice the length L3s of the second end core piece, and the remaining length of the first middle core portion.
  • the length L11s of is the length along the axial direction of the winding portion in the remaining portion of the first middle core portion
  • the length L12s of the remaining portion of the second middle core portion is the remaining length of the second middle core portion. It can be mentioned that the length is along the axial direction of the winding portion.
  • the above reactor easily enhances heat dissipation.
  • the reason is that the length L11s and the length L12s are more than twice the length L3s, and the second core composed of a dust compact having a relatively high thermal conductivity in the magnetic core. This is because it is easy to increase the proportion of parts.
  • the pressurizing direction at the time of molding may not be the direction along the axial direction of each middle core piece described above, but may be a direction orthogonal to both the axial direction of each middle core piece and the parallel direction of both middle core pieces. In this case, the second core portion having the length L11s and the length L12s more than twice the length L3s can be used. Further, when the pressurizing direction at the time of molding is the direction orthogonal to the above, it is easy to provide a notch portion or a chamfered portion at the second core portion at the time of molding.
  • the number of winding portions is one
  • the magnetic core is the first end core piece facing one end surface of the winding portion.
  • the second end core piece facing the other end surface of the winding portion, the middle core portion having a portion arranged inside the winding portion, and the outer periphery of the winding portion so as to sandwich the middle core portion.
  • first side core portion and a second side core portion arranged in the above, and the first core portion and the second core portion are combined in the axial direction of the winding portion, and the first core portion is It is mentioned that it has at least one selected from the group consisting of at least a part of the middle core part, at least a part of the first side core part, and at least a part of the second side core part.
  • the above reactor makes it easy to adjust the inductance and heat dissipation. Further, since the reactor can be constructed by combining the first core portion and the second core portion with respect to the winding portion along the axial direction of the winding portion, the reactor is excellent in manufacturing workability.
  • the second core portion is selected from the group consisting of the remaining portion of the middle core portion, the remaining portion of the first side core portion, and the remaining portion of the second side core portion.
  • the length L1s of the remaining portion of the middle core portion, the length L21s of the remaining portion of the first side core portion, and the length L22s of the remaining portion of the second side core portion are the lengths of the second end core pieces. It is not more than twice the length of L3s, and the length L1s of the remaining portion of the middle core portion is the length of the remaining portion of the middle core portion along the axial direction of the winding portion, and is the length of the remaining portion of the first side core portion.
  • L21s is the length of the remaining portion of the first side core portion along the axial direction of the winding portion
  • the length L22s of the remaining portion of the second side core portion is the winding of the remaining portion of the second side core portion. It can be mentioned that the length is along the axial direction of the rotating part.
  • the variation between the density of the second middle core piece, the density of the first side core piece, the density of the second side core piece, and the density of the second end core piece tends to be small.
  • the reason is that, as described above, when the length L1s, the length L21s, and the length L22s are not more than twice the length L3s, they act on each core piece at the time of molding the second core portion. It is easy to reduce the variation in pressure. Therefore, it is easy to manufacture the second core portion having a small variation in density.
  • the second core portion is selected from the group consisting of the remaining portion of the middle core portion, the remaining portion of the first side core portion, and the remaining portion of the second side core portion.
  • the length L1s of the remaining portion of the middle core portion, the length L21s of the remaining portion of the first side core portion, and the length L22s of the remaining portion of the second side core portion are the lengths of the second end core pieces. It is more than twice the length of L3s, and the length L1s of the remaining portion of the middle core portion is the length of the remaining portion of the middle core portion along the axial direction of the winding portion, and is the length of the remaining portion of the first side core portion.
  • L21s is the length of the remaining portion of the first side core portion along the axial direction of the winding portion
  • the length L22s of the remaining portion of the second side core portion is the winding of the remaining portion of the second side core portion. It can be mentioned that the length is along the axial direction of the rotating part.
  • the above reactor easily enhances heat dissipation.
  • the reason is that, as described above, when the length L1s, the length L21s, and the length L22s are more than twice the length L3s, the second core portion having excellent heat dissipation in the magnetic core This is because it is easy to increase the ratio.
  • the magnetic core has a gap portion provided between the first core portion and the second core portion.
  • the gap portion may be arranged inside the winding portion.
  • the gap portion is arranged inside the winding portion, the leakage flux penetrates into the winding portion and is arranged at the winding portion as compared with the case where it is arranged outside the winding portion. It is easy to reduce the generated eddy current loss.
  • the length of the winding portion in the gap portion along the axial direction is 2 mm or less.
  • the converter according to one form of the present disclosure includes the reactor according to any one of the above (1) to (15).
  • the converter Since the converter is equipped with the reactor, it does not become large and has excellent heat dissipation.
  • the power conversion device includes the converter of (16) above.
  • the power conversion device includes the converter, it does not become large and has excellent heat dissipation.
  • Embodiment 1 >> [Reactor]
  • the reactor 1 of the first embodiment will be described with reference to FIGS. 1 to 3.
  • the reactor 1 includes a coil 2 and a magnetic core 3.
  • the coil 2 has a tubular winding portion 21.
  • One of the features of the reactor 1 of this embodiment is that it satisfies the following requirements (a) to (d).
  • the magnetic core 3 is a combination of a first core portion 3f and a second core portion 3s.
  • the saturation magnetic flux densities of the first core portion 3f and the second core portion 3s satisfy a specific magnitude relationship.
  • the first core portion 3f has a first end core piece 33f facing one end face of the winding portion 21, and the second core portion 3s faces the other end face of the winding portion 21. It has a second end core piece 33s.
  • the lengths of the first end core piece 33f and the second end core piece 33s satisfy a specific magnitude relationship.
  • FIG. 3 for convenience of explanation, the coil 2 is shown by a chain double-dashed line. This point is the same in FIGS. 4 to 6 referred to in the second to fourth embodiments described later, and 9 to 12 referred to in the fifth to eighth embodiments, respectively.
  • the coil 2 has one hollow winding portion 21 as shown in FIGS. 1 and 2.
  • the number of winding portions 21 may be one as in the present embodiment, or may be two as in the fifth embodiment described later with reference to FIGS. 7 to 9.
  • the reactor 1 of the present embodiment has one winding portion 21 as compared with the reactor 1 of the fifth embodiment in which the two winding portions are arranged in parallel in the direction orthogonal to the axial direction of the winding portion.
  • the shape of the winding portion 21 may be a rectangular cylinder or a cylinder.
  • the rectangle includes a square.
  • the shape of the winding portion 21 of this embodiment is a rectangular cylinder. That is, the end face shape of the winding portion 21 is a rectangular frame shape. Since the shape of the winding portion 21 is a rectangular cylinder, it is easy to increase the contact area between the winding portion 21 and the installation target as compared with the case where the winding portion has a cylindrical shape having the same cross-sectional area. Therefore, the reactor 1 easily dissipates heat to the installation target via the winding portion 21. Moreover, the winding portion 21 is stable and easy to install on the installation target. The corners of the winding portion 21 are rounded.
  • the winding portion 21 of this example is configured by spirally winding one winding without a joint.
  • a known winding can be used.
  • the winding of this embodiment uses a covered flat wire.
  • the conductor wire of the covered flat wire is composed of a copper flat wire.
  • the insulating coating of the coated flat wire is made of enamel.
  • the winding portion 21 is composed of an edgewise coil in which a coated flat wire is wound edgewise.
  • One end 21a and the other end 21b of the winding portion 21 are stretched toward the outer peripheral side of the winding portion 21 in the present embodiment on one end side and the other end side in the axial direction of the winding portion 21, respectively.
  • the insulating coating of the one end 21a and the other end 21b of the winding portion 21 is peeled off to expose the conductor wire.
  • the exposed conductor wire is pulled out to the outside of the mold resin portion 4 described later, and the terminal member is connected to the exposed conductor wire. Illustration of terminal members is omitted.
  • An external device is connected to the coil 2 via this terminal member. The illustration of the external device is omitted. Examples of the external device include a power source that supplies electric power to the coil 2.
  • the configuration of the magnetic core 3 can be appropriately selected according to the number of winding portions 21 of the coil 2.
  • the magnetic core 3 of the present embodiment has a first end core piece 33f and a second end core piece 33s, a middle core portion 31, and a first side core portion 321 and a second side core portion 322.
  • the direction along the axial direction of the winding portion 21 is the first direction D1
  • the first side core portion 321 and the second side core portion 322 is the second direction D2
  • the direction orthogonal to both the second direction D2 and the second direction D2 is defined as the third direction D3.
  • the first end core piece 33f faces one end surface of the winding portion 21.
  • the second end core piece 33s faces the other end face of the winding portion 21. Facing means that the core piece and the end face of the winding portion 21 face each other.
  • the shape of the first end core piece 33f and the shape of the second end core piece 33s are thin prisms as shown in FIGS. 1 and 2.
  • the middle core portion 31 has a portion arranged inside the winding portion 21.
  • the shape of the middle core portion 31 may be a shape corresponding to the inner peripheral shape of the winding portion 21, and in this embodiment, it is a square columnar shape as shown in FIG.
  • the corner portion of the middle core portion 31 may be rounded along the inner peripheral surface of the corner portion of the winding portion 21.
  • the length of the middle core portion 31 along the first direction D1 is equivalent to the length of the winding portion 21 along the axial direction.
  • the length of the middle core portion 31 along the first direction D1 is the total length (L1f + L1s) of the length L1f of the first middle core piece 31f and the length L1s of the second middle core piece 31s, which will be described later.
  • the length of the middle core portion 31 along the first direction D1 does not include the length Lg of the gap portion 3g described later along the first direction D1. The same meaning applies to the lengths of other core parts and core pieces.
  • the length of the middle core portion 31 along the first direction D1 is shorter than the length of the first side core portion 321 along the first direction D1 and the length of the second side core portion 322 along the first direction D1. ..
  • the length of the first side core portion 321 along the first direction D1 is the total length (L21f + L21s) of the length L21f of the first side core piece 321f and the length L21s of the first side core piece 321s, which will be described later.
  • the length of the second side core portion 322 along the first direction D1 is the total length (L22f + L22s) of the length L22f of the second side core piece 322f and the length L22s of the second side core piece 322s, which will be described later.
  • the first direction D1 of the first side core portion 321 does not include the length along the first direction D1 of the gap portion.
  • the length of the middle core portion 31 along the first direction D1 is different from that of the present embodiment and is along the length along the first direction D1 of the first side core portion 321 and along the first direction D1 of the second side core portion 322. It may be equal to the length.
  • the middle core portion 31 is composed of two core pieces, a first middle core piece 31f and a second middle core piece 31s, as in the third embodiment described later with reference to this embodiment and FIG. 5, and see FIG. Examples thereof include a case where the first middle core piece 31f is formed as in the case where the first middle core piece 31f is described as in the second embodiment described later and the fourth embodiment described later with reference to FIG.
  • first side core portion 321 and the second side core portion 322 are arranged so as to face each other so as to sandwich the middle core portion 31.
  • the first side core portion 321 and the second side core portion 322 are arranged on the outer periphery of the winding portion 21.
  • the shape of the first side core portion 321 and the shape of the second side core portion 322 are the same shape and are thin prisms.
  • the length (L21f + L21s) of the first side core portion 321 along the first direction D1 and the length (L22f + L22s) of the second side core portion 322 along the first direction D1 are the winding portions. It is longer than the length along the axial direction of 21.
  • the length of the first side core portion 321 along the first direction D1 and the length of the second side core portion 322 along the first direction D1 may be equal to the length along the axial direction of the winding portion 21. ..
  • the first side core portion 321 is composed of two core pieces, a first side core piece 321f and a first side core piece 321s, as in the present embodiment and the fourth embodiment, and a case where the first side core portion 321 is composed of two core pieces, as in the second embodiment and the third embodiment. As described above, there is a case where the first side core piece is composed of 321f.
  • the second side core portion 322 is composed of two core pieces, a second side core piece 322f and a second side core piece 322s, as in the present embodiment and the fourth embodiment, and a case where the second side core portion 322 is composed of two core pieces, as in the second embodiment and the third embodiment. As described above, there is a case where it is composed of one second side core piece 322f.
  • the total of the cross-sectional area of the first side core portion 321 and the cross-sectional area of the second side core portion 322 is the same as the cross-sectional area of the middle core portion 31. That is, the sum of the length of the first side core portion 321 along the second direction D2 and the length of the second side core portion 322 along the second direction D2 is the length of the middle core portion 31 along the second direction D2. Equivalent to.
  • the magnetic core 3 is a combination of the first core portion 3f and the second core portion 3s.
  • the combination of the first core portion 3f and the second core portion 3s can be various combinations by appropriately selecting the shape of the first core portion 3f and the shape of the second core portion 3s.
  • the shape of the first core portion 3f and the shape of the second core portion 3s may be symmetrical, but are preferably asymmetrical with each other. Symmetry means that the shape and size are the same. Asymmetric means that the shape is different. The asymmetry gives a wide range of choices between the shape of the first core portion 3f and the shape of the second core portion 3s. In this embodiment, the shape of the first core portion 3f and the shape of the second core portion 3s are asymmetric.
  • the first core portion 3f and the second core portion 3s are divided into the first direction D1 as shown in FIG.
  • the combination of the first core portion 3f and the second core portion 3s is an EE type in this embodiment.
  • the above combination may be an EI type as in the second embodiment.
  • the above combination may be an ET type as in the third embodiment.
  • the above combination may be an EU type as in the fourth embodiment.
  • the above combination may be FF type, FL type, UT type, or the like.
  • a gap portion 3g which will be described later, may or may not be provided between the first core portion 3f and the second core portion 3s.
  • the first core portion 3f may have at least the first end core piece 33f.
  • the first core portion 3f is selected from the group consisting of at least a part of the middle core portion 31, at least a part of the first side core portion 321 and at least a part of the second side core portion 322, in addition to the first end core piece 33f. It is mentioned to have at least one to be done.
  • the shape of the first core portion 3f is T-shaped.
  • the shape of the first core portion 3f is L-shaped. Is.
  • the first core portion 3f has a first end core piece 33f, at least a part of the middle core portion 31, and at least a part of the first side core portion 321 or at least a part of the second side core portion 322, the first core The shape of the portion 3f is F-shaped.
  • the shape of the first core portion 3f is U-shaped. It is in the shape.
  • the first core portion 3f has a first end core piece 33f, at least a part of the middle core portion 31, at least a part of the first side core portion 321 and at least a part of the second side core portion 322, the first The shape of the core portion 3f is E-shaped.
  • the shape of the first core portion 3f of this embodiment is E-shaped. That is, the first core portion 3f of the present embodiment includes a first end core piece 33f, at least a part of the middle core portion 31, at least a part of the first side core portion 321 and at least a part of the second side core portion 322. Have. Specifically, the first core portion 3f of the present embodiment includes a first end core piece 33f, a part of the middle core portion 31, a part of the first side core portion 321 and a part of the second side core portion 322. Have. More specifically, the first core portion 3f of the present embodiment includes a first end core piece 33f, a first middle core piece 31f, a first side core piece 321f, and a second side core piece 322f.
  • the first core portion 3f is a molded body in which the first end core piece 33f, the first middle core piece 31f, the first side core piece 321f, and the second side core piece 322f are integrated.
  • the first end core piece 33f connects the first middle core piece 31f, the first side core piece 321f, and the second side core piece 322f.
  • the first side core piece 321f and the second side core piece 322f are provided at both ends of the first end core piece 33f.
  • the first middle core piece 31f is provided in the center of the first end core piece 33f.
  • the shape of the first end core piece 33f is a thin prismatic shape as described above.
  • the shape of the first middle core piece 31f is a square columnar shape.
  • the shape of the first side core piece 321f and the second side core piece 322f is a thin prismatic shape.
  • the second core portion 3s has at least the second end core piece 33s like the first core portion 3f.
  • the second core portion 3s includes the remaining portion of the middle core portion 31, the remaining portion of the first side core portion 321 and the second core portion 3s in addition to the second end core piece 33s. It may have at least one selected from the group consisting of the rest of the two-side core portion 322.
  • the shape of the second core portion 3s is I-shaped.
  • the shape of the second core portion 3s is T-shaped.
  • the shape of the second core portion 3s is L-shaped.
  • the shape of the second core portion 3s is F.
  • the shape of the second core portion 3s is in the shape of a letter.
  • the shape of the second core portion 3s is U-shaped.
  • the shape of the second core portion 3s is It is E-shaped.
  • the shape of the second core portion 3s of this embodiment is E-shaped. That is, the second core portion 3s of the present embodiment has a second end core piece 33s, a remaining portion of the middle core portion 31, a remaining portion of the first side core portion 321 and a remaining portion of the second side core portion 322. Specifically, the second core portion 3s of the present embodiment includes a second end core piece 33s, a second middle core piece 31s, a first side core piece 321s, and a second side core piece 322s.
  • the second core portion 3s is a molded body in which the second end core piece 33s, the second middle core piece 31s, the first side core piece 321s, and the second side core piece 322s are integrated.
  • the second end core piece 33s connects the second middle core piece 31s, the first side core piece 321s, and the second side core piece 322s.
  • the first side core piece 321s and the second side core piece 322s are provided at both ends of the second end core piece 33s.
  • the second middle core piece 31s is provided in the center of the second end core piece 33s.
  • the shape of the second end core piece 33s is a thin prismatic shape as described above.
  • the shape of the second middle core piece 31s is a square columnar shape.
  • the shape of the first side core piece 321s and the second side core piece 322s is a thin prismatic shape.
  • the size of the first core portion 3f and the size of the second core portion 3s are different. Specifically, there is a portion in which the length of each core piece of the first core portion 3f along the first direction D1 and the length of each core piece of the second core portion 3s along the first direction D1 are different. The length of each core piece of the first core portion 3f along the second direction D2 and the length of each core piece of the second core portion 3s along the second direction D2 are the same as each other. The length of each core piece of the first core portion 3f along the third direction D3 and the length of each core piece of the second core portion 3s along the third direction D3 are the same as each other.
  • the length L1f of the first middle core piece 31f along the first direction D1, the length L21f of the first side core piece 321f along the first direction D1, and the second side core piece 322s are the same and longer than the length L1f. In the first core portion 3f, the length L21f and the length L22f may be the same, and the length L1f may be longer than the length L21f and the length L22f.
  • the length L1s of the second middle core piece 31s along the first direction D1, the length L21s of the first side core piece 321s along the first direction D1, and the second side core piece 322s are the same, or all lengths may be the same. In this embodiment, the length L21s and the length L22s are the same and longer than the length L1s. In the second core portion 3s, the length L21s and the length L22s may be the same, and the length L1s may be longer than the length L21s and the L22s.
  • the length L1f and the length L1s may be different as in the present embodiment, or may be the same as in the present embodiment. In this embodiment, the length L1f is longer than the length L1s.
  • the length of the first middle core piece 31f along the second direction D2 and the length of the second middle core piece 31s along the second direction D2 are the same as each other as described above.
  • the length of the first middle core piece 31f along the third direction D3 and the length of the second middle core piece 31s along the third direction D3 are the same as each other as described above.
  • the length L21f and the length L21s may be different as in the present embodiment, or may be different from the present embodiment and may be the same. In this embodiment, the length L21f is longer than the length L21s.
  • the length of the first side core piece 321f of the first core portion 3f along the second direction D2 and the length of the first side core piece 321s of the second core portion 3s along the second direction D2 are mutual as described above. It is the same.
  • the length of the first side core piece 321f of the first core portion 3f along the third direction D3 and the length of the first side core piece 321s of the second core portion 3s along the third direction D3 are mutual as described above. It is the same.
  • the length L22f and the length L22s may be different as in the present embodiment, or may be different from the present embodiment and may be the same. In this embodiment, the length L22f is longer than the length L22s.
  • the length of the second side core piece 322f of the first core portion 3f along the second direction D2 and the length of the second side core piece 322s of the second core portion 3s along the second direction D2 are mutual as described above. It is the same.
  • the length of the second side core piece 322f of the first core portion 3f along the third direction D3 and the length of the second side core piece 322s of the second core portion 3s along the third direction D3 are mutual as described above. It is the same.
  • the length L3s of the second end core piece 33s along the first direction D1 is shorter than the length L3f of the first end core piece 33f along the first direction D1. Therefore, the length of the reactor 1 along the first direction D1 can be shortened, so that the reactor 1 is small.
  • the length L3s is preferably ⁇ the length L3f x (saturation magnetic flux density Bf of the first core portion 3f / saturation magnetic flux density Bs of the second core portion 3s) ⁇ or more.
  • the length of the first end core piece 33f along the second direction D2 and the length of the second end core piece 33s along the second direction D2 are the same as each other, and the winding portion 21 Longer than the length along the second direction D2.
  • the length of the first end core piece 33f along the third direction D3 and the length of the second end core piece 33s along the third direction D3 are the same as each other, and the winding portion 21 It is shorter than the length along the third direction D3.
  • the length of the first end core piece 33f along the third direction D3 and the length of the second end core piece 33s along the third direction D3 are longer than the length of the winding portion 21 along the third direction D3. It may be the same or it may be the same.
  • the second core portion 3s is composed of a powder compact.
  • the length L1s, the length L21s, and the length L22s may be twice or less or more than twice the length L3s. ..
  • the compaction compact is formed by compression molding the raw material powder.
  • the pressurizing direction at the time of molding depends on the shape and size of the powder compact, and may be a direction along the first direction D1 or a direction along the third direction D3.
  • the length L1s, the length L21s, and the length L22s are twice or less the length L3s, the second core portion.
  • the pressurizing direction at the time of molding is the direction along the first direction D1
  • the length L1s, the length L21s, and the length L22s are further preferably 1.8 times or less of the length L3s. In particular, 1.6 times or less is preferable.
  • the length L1s, the length L21s, and the length L22s are, for example, one or more times the length L3s.
  • the second core portion 3s having the length L1s, the length L21s, and the length L22s less than twice the length L3s is manufactured.
  • the second core portion 3s having a length of more than twice the length L3s it is also possible to manufacture the second core portion 3s having a length of more than twice the length L3s.
  • the magnetic core 3 is composed of a dust compact having a relatively high thermal conductivity. Since it is easy to increase the ratio of the two core portions 3s, the reactor 1 can easily improve the heat dissipation.
  • the notch portion or the chamfered portion at the time of molding is compared with the case where the pressurizing direction at the time of molding is along the first direction D1. Is easy to provide in the second core portion 3s.
  • the length L1s, the length L21s, and the length L22s are more than 2.5 times, particularly 3 times, the length L3s. Can be super.
  • the length L1s, the length L21s, and the length L22s are, for example, five times or less the length L3s.
  • the length L1s, the length L21s, and the length L22s are twice or less the length L3s.
  • the first core portion 3f and the second core portion 3s are in contact with the end face of the first side core piece 321f of the first core portion 3f and the end face of the first side core piece 321s of the second core portion 3s, and the first core portion 3f
  • the end face of the second side core piece 322f and the end face of the second side core piece 322s of the second core portion 3s are combined so as to be in contact with each other.
  • first core portion 3f and the second core portion 3s are the first between the end face of the first side core piece 321f of the first core portion 3f and the end face of the first side core piece 321s of the second core portion 3s. It may be combined so that a space is provided between the end surface of the second side core piece 322f of the core portion 3f and the end surface of the second side core piece 322s of the second core portion 3s. When combined in this way, since the above-mentioned length relationship is satisfied, a space is also provided between the end face of the first middle core piece 31f and the end face of the second middle core piece 31s.
  • the distance between the end face of the first middle core piece 31f and the end face of the second middle core piece 31s is the distance between the end face of the first side core piece 321f and the end face of the first side core piece 321s, and the second side core. It is larger than the distance between the end face of the piece 322f and the end face of the second side core piece 322s.
  • the first core portion 3f and the second core portion 3s may be combined by a mold resin portion 4 or the like, which will be described later.
  • the gap portion 3g is formed by the mold resin portions 4 filled at the above intervals.
  • the first core portion 3f and the second core portion 3s satisfy the saturation magnetic flux density of the first core portion 3f ⁇ the saturation magnetic flux density of the second core portion 3s.
  • the length L3s of the second end core piece 33s can be made shorter than the length L3f of the first end core piece 33f. .. Even if the length L3s is shorter than the length L3f, the saturation magnetic flux density of the second core portion 3s having the second end core piece 33s is higher than the saturation magnetic flux density of the first core portion 3f having the first end core piece 33f. This is because it is easy to reduce the variation between the magnetic flux density of the second core portion 3s and the magnetic flux density of the first core portion 3f because the size is large.
  • the first core portion 3f and the second core portion 3s satisfy the relative magnetic permeability of the first core portion 3f ⁇ the relative magnetic permeability of the second core portion 3s.
  • the first core portion 3f and the second core portion 3s satisfy the above-mentioned magnitude relationship of the relative magnetic permeability, so that a large gap portion 3g is formed between the first core portion 3f and the second core portion 3s. It is easy to adjust the inductance without intervention. Further, since the reactor 1 does not have to pass through the long gap portion 3g having the length Lg between the first core portion 3f and the second core portion 3s, the leakage flux penetrates into the winding portion 21 and winds.
  • the long gap portion 3g having a length Lg means, for example, more than 2 mm. Moreover, even if the length L3s of the second end core piece 33s is shorter than the length L3f of the first end core piece 33f, the reactor 1 can effectively suppress the leakage flux of the reactor 1 to the outside. Therefore, the problem that the leakage flux from the reactor 1 affects the peripheral devices of the reactor 1 is suppressed.
  • the relative magnetic permeability of the first core portion 3f is preferably 50 or less, and the specific magnetic permeability of the second core portion 3s is preferably 50 or more. The reason is that it is easy to adjust the inductance.
  • the relative magnetic permeability of the first core portion 3f is further preferably 45 or less, and particularly preferably 40 or less.
  • the relative magnetic permeability of the first core portion 3f is, for example, 5 or more.
  • the relative magnetic permeability of the second core portion 3s is more preferably 100 or more, and particularly preferably 150 or more.
  • the relative magnetic permeability of the second core portion 3s is, for example, 500 or less.
  • the first core portion 3f and the second core portion 3s are "iron loss of the first core portion 3f ⁇ iron loss of the second core portion 3s" and "thermal conductivity of the first core portion 3f ⁇ second core portion". It is preferable to satisfy the "thermal conductivity of 3s". By satisfying this magnitude relationship, the temperature of the reactor 1 is unlikely to rise.
  • the second core portion 3s has a large iron loss and easily generates heat, but has a large thermal conductivity and high heat dissipation, and the first core portion 3f has a small thermal conductivity and low heat dissipation, but the iron loss is small and heat is generated. Because it is difficult to do.
  • the difference between the thermal conductivity of the first core portion 3f and the thermal conductivity of the second core portion 3s is, for example, preferably 1 W / m ⁇ K or more, more preferably 3 W / m ⁇ K or more, and particularly 5 W / m. -K or higher is preferable.
  • the difference in thermal conductivity is, for example, 20 W / m ⁇ K or less.
  • the thermal conductivity of the first core portion 3f is, for example, preferably 1 W / m ⁇ K or more, more preferably 2 W / m ⁇ K or more, and particularly preferably 3 W / m ⁇ K or more.
  • the thermal conductivity of the first core portion 3f is, for example, 5 W / m ⁇ K or less.
  • the thermal conductivity of the second core portion 3s is, for example, preferably 5 W / m ⁇ K or more, more preferably 10 W / m ⁇ K or more, and particularly preferably 15 W / m ⁇ K or more.
  • the thermal conductivity of the second core portion 3s is, for example, 20 W / m ⁇ K or less.
  • the saturation magnetic flux density is calculated as follows. A ring-shaped measurement sample is cut out from each of the first core portion and the second core portion. A magnetic field of 795.8 kA / m is applied to each measurement sample by an electromagnet to obtain the magnetic flux density when the magnetic saturation is sufficient.
  • the relative magnetic permeability is obtained as follows using each of the above measurement samples. Each of the above measurement samples is wound with 300 turns on the primary side and 20 turns on the secondary side.
  • the magnetization curve here is a so-called DC magnetization curve.
  • Thermal conductivity is obtained by measuring each of the first core part and the second core part by the temperature gradient method or the laser flash method.
  • the first core portion 3f and the second core portion 3s are made of a molded body.
  • the molded product include a powder compacted product and a composite material molded product.
  • the molded bodies constituting the first core portion 3f and the second core portion 3s are made of different materials.
  • the materials different from each other include not only the case where the materials of the individual components of each core portion are different, but also the case where the materials of the individual components are the same but the contents of the plurality of components are different.
  • the first core portion 3f and the second core portion 3s are made of a dust compact, they are made of different materials if the material and content of the soft magnetic powder constituting the dust compact are different. It is assumed that it has been done.
  • first core portion 3f and the second core portion 3s are composed of a molded body of a composite material, if at least one of the soft magnetic powder and the resin constituting the composite material is different, or the soft magnetic Even if the materials of the powder and the resin are the same, if the contents of the soft magnetic powder and the resin are different, it is assumed that they are composed of different materials.
  • these core portions may be composed of a laminated body.
  • the compaction compact is made by compression molding soft magnetic powder.
  • the powder compact can increase the proportion of the soft magnetic powder in the core piece as compared with the composite material. Therefore, the powder compact easily enhances the magnetic characteristics. Examples of magnetic characteristics include saturation magnetic flux density and relative magnetic permeability. Further, the powder compact has excellent heat dissipation because the amount of resin is small and the amount of soft magnetic powder is large as compared with the molded body of composite material.
  • the content of the magnetic powder in the compaction compact is, for example, 85% by volume or more and 99.99% by volume or less. This content is a value when the powder compact is 100% by volume.
  • the composite material consists of soft magnetic powder dispersed in the resin.
  • the composite material is obtained by filling a mold with a fluid material in which soft magnetic powder is dispersed in an unsolidified resin and curing the resin.
  • the content of the soft magnetic powder in the resin can be easily adjusted. Therefore, the composite material can easily adjust the magnetic properties.
  • the composite material is easier to form even in a complicated shape as compared with the powder compact.
  • the content of the soft magnetic powder in the molded product of the composite material is, for example, 20% by volume or more and 80% by volume or less.
  • the content of the resin in the molded product of the composite material is, for example, 20% by volume or more and 80% by volume or less.
  • the laminated body is made by laminating a plurality of magnetic thin plates.
  • the magnetic thin plate has an insulating coating.
  • Examples of the magnetic thin plate include an electromagnetic steel plate.
  • Examples of the particles constituting the soft magnetic powder include soft magnetic metal particles, coated particles having an insulating coating on the outer periphery of the soft magnetic metal particles, and soft magnetic non-metal particles.
  • Examples of the soft magnetic metal include pure iron and iron-based alloys. Examples of the iron-based alloy include Fe—Si alloys and Fe—Ni alloys. Examples of the insulating coating include phosphate and the like. Examples of the soft magnetic non-metal include ferrite and the like.
  • Examples of the resin of the composite material include a thermosetting resin and a thermoplastic resin.
  • examples of the thermosetting resin include epoxy resin, phenol resin, silicone resin, urethane resin and the like.
  • examples of the thermoplastic resin include polyphenylene sulfide resin, polyamide resin, liquid crystal polymer, polyimide resin, and fluororesin.
  • examples of the polyamide resin include nylon 6, nylon 66, nylon 9T and the like.
  • These resins may contain a ceramic filler.
  • the ceramic filler include alumina and silica.
  • the resin containing these ceramic fillers is excellent in heat dissipation and electrical insulation.
  • the content of the soft magnetic powder in the compaction compact or the composite compact is considered to be equivalent to the area ratio of the soft magnetic powder in the cross section of the compact.
  • the content of the soft magnetic powder in the molded product is determined as follows. An observation image is acquired by observing the cross section of the molded product with an SEM (scanning electron microscope). The SEM magnification shall be 200 times or more and 500 times or less. The number of observation images acquired shall be 10 or more. The total cross-sectional area shall be 0.1 cm 2 or more. One observation image may be acquired for each cross section, or a plurality of observation images may be acquired for each cross section. Each of the acquired observation images is image-processed to extract the outline of the particles. Examples of the image processing include binarization processing. The area ratio of the soft magnetic particles is calculated in each observation image, and the average value of the area ratio is obtained. The average value is regarded as the content of the soft magnetic powder.
  • the first core portion 3f is composed of a molded body of a composite material
  • the second core portion 3s is composed of a powder compact. Since the first core portion 3f is composed of a molded body of a composite material and the second core portion 3s is composed of a powder compact, the above-mentioned length is formed between the first core portion 3f and the second core portion 3s. It is easy to adjust the inductance without passing through the long gap portion 3g of Lg, and it is easy to adjust the heat dissipation.
  • the second core portion 3s is composed of a dust compact having a relatively high thermal conductivity, so that the heat dissipation property can be easily improved.
  • the gap portion 3g is composed of a member made of a material having a smaller relative magnetic permeability than the first core portion 3f and the second core portion 3s.
  • the gap portion 3g is composed of a part of the mold resin portion 4 described later.
  • the gap portion 3g may be an air gap, unlike the present embodiment.
  • the location of the gap portion 3g is at least one of the outside of the winding portion 21 and the inside of the winding portion 21. That is, in the magnetic core 3 of the present embodiment, the gap portion 3g is arranged between the first side core piece 321f and the first side core piece 321s, between the second side core piece 322f and the second side core piece 322s, and first. At least one place between the middle core piece 31f and the second middle core piece 31s can be mentioned. It is preferable that the gap portion 3g is arranged inside the winding portion 21 as in the present embodiment. That is, it is preferable that the gap portion 3g is provided between the first middle core piece 31f and the second middle core piece 31s.
  • the gap portion 3g is provided inside the winding portion 21, the leakage flux penetrates into the winding portion 21 and the winding portion 21 is provided as compared with the case where the gap portion 3g is provided outside the winding portion 21. It is easy to reduce the eddy current loss generated in.
  • the length Lg of the gap portion 3 g is preferably 2 mm or less, for example.
  • the length Lg means the length of one gap portion 3g. That is, if the length Lg of each gap portion 3g is 2 mm or less, the total length Lg of the plurality of gap portions 3g may be more than 2 mm.
  • the length Lg of the gap portion 3g arranged inside the winding portion 21 is preferably 2 mm or less.
  • the length Lg is more preferably 1.5 mm or less, and particularly preferably 1.0 mm or less.
  • the length Lg may be, for example, 0.1 mm or more.
  • the length Lg is preferably 0.3 mm or more. When the length Lg is 0.1 mm or more and further 0.3 mm, it is easy to secure a predetermined inductance.
  • the reactor 1 preferably further has a mold resin portion 4 as shown in FIG. In FIG. 3, the mold resin portion is omitted for convenience of explanation.
  • the mold resin portion 4 covers at least a part of the magnetic core 3.
  • the mold resin portion 4 may cover the outer circumference of the magnetic core 3 and not the outer circumference of the coil 2, or may cover both the outer circumference of the magnetic core 3 and the outer circumference of the coil 2.
  • the mold resin portion 4 of this embodiment covers the outer circumference of the union of the coil 2 and the magnetic core 3. Therefore, the above union is protected from the external environment.
  • the mold resin portion 4 of this embodiment is provided between the coil 2 and the magnetic core 3 and between the first core portion 3f and the second core portion 3s.
  • the mold resin portion 4 provided between the first core portion 3f and the second core portion 3s constitutes the gap portion 3g.
  • the coil 2 and the magnetic core 3 are integrated by the mold resin portion 4.
  • Examples of the resin of the mold resin portion 4 include the same resin as the resin of the composite material described above.
  • the resin of the mold resin portion 4 may contain a ceramic filler as in the case of the composite material.
  • the reactor 1 may include at least one of a case, an adhesive layer, and a holding member.
  • the case houses a combination of the coil 2 and the magnetic core 3 inside.
  • the union in the case may be embedded by a sealing resin portion.
  • the adhesive layer fixes the union to the mounting surface, the union to the inner bottom surface of the case, the case to the mounting surface, and the like.
  • the holding member is provided between the coil 2 and the magnetic core 3 to ensure insulation between the coil 2 and the magnetic core 3.
  • the length L3s of the second end core piece 33s is shorter than the length L3f of the first end core piece 33f, so that the length along the first direction D1 can be reduced. Further, the inductance of the reactor 1 of this embodiment can be adjusted. Since the saturation magnetic flux density of the second core portion 3s is larger than the saturation magnetic flux density of the first core portion 3f of the reactor 1 of the present embodiment, there is a variation between the magnetic flux density of the first core portion 3f and the magnetic flux density of the second core portion 3s. This is because it is easy to make the size smaller.
  • the inductance can be adjusted without increasing the length Lg of the gap portion 3g between the first core portion 3f and the second core portion 3s.
  • the magnetic core 3 of the reactor 1 of the present embodiment is a combination of a first core portion 3f composed of a molded body of a composite material and a second core portion 3s composed of a dust compact. ..
  • the first core portion 3f and the second core portion 3s of the magnetic core 3 are made of different materials, so that the heat dissipation property can be easily adjusted and enhanced. Further, the reactor 1 of the present embodiment can be suitably used for a reactor that is cooled by a cooling member having a biased cooling performance.
  • the second core portion 3s having a high thermal conductivity is arranged on the side where the cooling performance of the cooling member is low, and the first core portion 3f having a low thermal conductivity is arranged on the side where the cooling performance of the cooling member is high.
  • the first core portion 3f and the second core portion 3s are uniformly cooled, and the maximum temperature of the magnetic core 3 is reduced.
  • the reactor 1 Since the maximum temperature of the magnetic core 3 is reduced in this way, the reactor 1 has a low loss. Further, since the reactor 1 is easy to adjust and enhance the heat dissipation property as described above, it is not necessary to provide a cooling pipe as in the conventional reactor described above, so that it is easy to reduce the size.
  • Embodiment 2 Reactor 1 of the second embodiment will be described with reference to FIG.
  • the reactor 1 of the present embodiment is different from the reactor 1 of the first embodiment in that the combination of the first core portion 3f and the second core portion 3s is EI type.
  • the following description will focus on the differences from the first embodiment.
  • the description of the configuration similar to that of the first embodiment may be omitted.
  • FIG. 4 the mold resin portion is omitted for convenience of explanation. This point is the same in FIGS. 5 and 6 referred to in the third and fourth embodiments described later, and in FIG. 9 referred to in the fifth embodiment, respectively.
  • the magnetic core 3 has a first end core piece 33f and a second end core piece 33s similar to those in the first embodiment. Further, the magnetic core 3 has a middle core portion 31, a first side core portion 321 and a second side core portion 322, which are different from those in the first embodiment.
  • the middle core portion 31 is composed of one first middle core piece 31f.
  • the first side core portion 321 is composed of one first side core piece 321f.
  • the second side core portion 322 is composed of one second side core piece 322f.
  • the length L1f along the first direction D1 of the middle core portion 31 is from the length L21f along the first direction D1 of the first side core portion 321 and the length L22f along the first direction D1 of the second side core portion 322. Is also short.
  • the shape of the first core portion 3f is E-shaped.
  • the first core portion 3f is a molded body in which the first end core piece 33f, the first middle core piece 31f, the first side core piece 321f, and the second side core piece 322f are integrally formed.
  • the length L21f of the first side core piece 321f along the first direction D1 and the length L22f of the second side core piece 322f along the first direction D1 are the same, and the length L22f of the first middle core piece 31f is the first direction D1. It is longer than the length L1f along.
  • the length L21f and the length L22f of the present embodiment are longer than the length L21f and the length L22f of the first embodiment, respectively, and longer than the axial length of the winding portion 21.
  • the first core portion 3f is composed of a molded body of a composite material as in the first embodiment.
  • the shape of the second core portion 3s is I-shaped.
  • the second core portion 3s is composed of a second end core piece 33s.
  • the length L3s of the second end core piece 33s along the first direction D1 is shorter than the length L3f of the first end core piece 33f along the first direction D1.
  • the length L3s is preferably ⁇ the length L3f ⁇ (saturation magnetic flux density Bf of the first core portion 3f / saturation magnetic flux density Bs of the second core portion 3s) ⁇ or more, as in the first embodiment.
  • the second core portion 3s is made of a powder compact as in the first embodiment.
  • the first core portion 3f and the second core portion 3s are the end face of the first side core piece 321f and the end face of the second side core piece 322f of the first core portion 3f, and the second end core piece 33s of the second core portion 3s. It is combined so that it touches the end face of. When combined in this way, since the above-mentioned length relationship is satisfied, a space is provided between the end face of the first middle core piece 31f of the first core portion 3f and the end face of the second end core piece 33s. ..
  • the magnitude relation of the saturation magnetic flux density of the first core portion 3f and the second core portion 3s, the magnitude relation of the relative magnetic permeability, the magnitude relation of the iron loss, and the magnitude relation of the thermal conductivity are the same as those in the first embodiment.
  • the gap portion 3g is composed of a part of a mold resin portion (not shown). Unlike the first embodiment, the gap portion 3g is arranged between the end face of the first middle core piece 31f and the end face of the second end core piece 33s, and is outside the winding portion 21.
  • the length Lg of the gap portion 3g along the first direction D1 is 2 mm or less as in the first embodiment.
  • the reactor 1 of the present embodiment can easily adjust the inductance and heat dissipation without increasing the size.
  • the effect of reducing the eddy current loss due to the reduction of the leakage flux is lower than that of the reactor 1 of the first embodiment.
  • the density distribution of the second core portion 3s is more unlikely to occur as compared with the reactor 1 of the first embodiment. This is because the second core portion 3s is composed of only the second end core piece 33s, so that the pressure at the time of molding the second core portion 3s is unlikely to vary.
  • Embodiment 3 [Reactor] Reactor 1 of the third embodiment will be described with reference to FIG.
  • the reactor 1 of the present embodiment is different from the reactor 1 of the first embodiment in that the combination of the first core portion 3f and the second core portion 3s is an ET type.
  • the magnetic core 3 has the same first end core piece 33f, second end core piece 33s, and middle core portion 31 as in the first embodiment. Further, the magnetic core 3 has a first side core portion 321 and a second side core portion 322, which are different from those in the first embodiment.
  • the middle core portion 31 is composed of a first middle core piece 31f and a second middle core piece 31s.
  • the first side core portion 321 is composed of one first side core piece 321f.
  • the second side core portion 322 is composed of one second side core piece 322f.
  • the length (L1f + L1s) of the middle core portion 31 along the first direction D1 is the length along the first direction D1 of the first side core portion 321 or the length along the first direction D1 of the second side core portion 322. It is shorter than L22f.
  • the shape of the first core portion 3f is E-shaped.
  • the first core portion 3f is a molded body in which the first end core piece 33f, the first middle core piece 31f, the first side core piece 321f, and the second side core piece 322f are integrally formed.
  • the length L21f of the first side core piece 321f along the first direction D1 and the length L22f of the second side core piece 322f along the first direction D1 are the same, and the length L22f of the first middle core piece 31f is the first direction D1. It is longer than the length L1f along.
  • the length L21f and the length L22f of the present embodiment are longer than the length L21f and the length L22f of the first embodiment and longer than the axial length of the winding portion 21.
  • the length L1f may be different from the length L1s along the first direction D1 of the second middle core piece 31s, which will be described later, as in the present embodiment, and is the same as the length L1s unlike the present embodiment. It may be.
  • the length L1f of the present embodiment is the same as the L1f of the first embodiment, and is longer than the length L1s of the present embodiment.
  • the first core portion 3f is composed of a molded body of a composite material as in the first embodiment.
  • the shape of the second core portion 3s is T-shaped.
  • the second core portion 3s is a molded body in which the second end core piece 33s and the second middle core piece 31s are integrally formed.
  • the length L3s of the second end core piece 33s along the first direction D1 is shorter than the length L3f of the first end core piece 33f along the first direction D1.
  • the length L3s is preferably ⁇ the length L3f ⁇ (saturation magnetic flux density Bf of the first core portion 3f / saturation magnetic flux density Bs of the second core portion 3s) ⁇ or more, as in the first embodiment.
  • the length L1s of the present embodiment is the same as the length L1s of the first embodiment, and is shorter than the length L1f of the present embodiment.
  • the length L1s is twice or less the length L3s as in the first embodiment.
  • the second core portion 3s is made of a powder compact as in the first embodiment.
  • the first core portion 3f and the second core portion 3s are the end face of the first side core piece 321f and the end face of the second side core piece 322f of the first core portion 3f, and the second end core piece 33s of the second core portion 3s. It is combined so that it touches the end face of. When combined in this way, since the above-mentioned length relationship is satisfied, between the end face of the first middle core piece 31f of the first core portion 3f and the end face of the second middle core piece 31s of the second core portion 3s. There is an interval.
  • the magnitude relation of the saturation magnetic flux density of the first core portion 3f and the second core portion 3s, the magnitude relation of the relative magnetic permeability, the magnitude relation of the iron loss, and the magnitude relation of the thermal conductivity are the same as those in the first embodiment.
  • the gap portion 3g is composed of a part of a mold resin portion (not shown). As in the first embodiment, the gap portion 3g is arranged inside the winding portion 21 between the end face of the first middle core piece 31f and the end face of the second middle core piece 31s.
  • the length Lg of the gap portion 3g along the first direction D1 is 2 mm or less as in the first embodiment.
  • the reactor 1 of the present embodiment can easily adjust the inductance and heat dissipation without increasing the size.
  • Embodiment 4 >> [Reactor]
  • the reactor 1 of the fourth embodiment will be described with reference to FIG.
  • the reactor 1 of the present embodiment is different from the reactor 1 of the first embodiment in that the combination of the first core portion 3f and the second core portion 3s is an EU type.
  • the magnetic core 3 has the same first end core piece 33f, second end core piece 33s, first side core portion 321 and second side core portion 322 as in the first embodiment. Further, the magnetic core 3 has a middle core portion 31 different from that of the first embodiment.
  • the first side core portion 321 is composed of a first side core piece 321f and a first side core piece 321s.
  • the second side core portion 322 is composed of a second side core piece 322f and a second side core piece 322s.
  • the middle core portion 31 is composed of one first middle core piece 31f.
  • the length L1f along the first direction D1 of the middle core portion 31 is the length (L21f + L21s) along the first direction D1 of the first side core portion 321 and the length along the first direction D1 of the second side core portion 322. It is shorter than (L22f + L22s).
  • the shape of the first core portion 3f is E-shaped.
  • the first core portion 3f is a molded body in which the first end core piece 33f, the first middle core piece 31f, the first side core piece 321f, and the second side core piece 322f are integrally formed.
  • the length L21f of the first side core piece 321f along the first direction D1 and the length L22f of the second side core piece 322f along the first direction D1 are the same.
  • the length L1f of the first middle core piece 31f along the first direction D1 is longer than the length L21f and the L22f.
  • the length L21f and the length L22f are the first of the length L21s and the second side core piece 322f along the first direction D1 of the first side core piece 321s of the second core portion 3s described later as in this embodiment, respectively. It may be different from the length L22s along the direction D1, or may be the same as the length L21s and the length L22s unlike the present embodiment.
  • the length L21f and the length L22f of the present embodiment are the same as the length L21f and the length L22f of the first embodiment, respectively, and are longer than the length L21s and the length L22s of the present embodiment.
  • the L1f is longer than the L1f of the first embodiment and is equivalent to the axial length of the winding portion 21.
  • the first core portion 3f is composed of a molded body of a composite material as in the first embodiment.
  • the shape of the second core portion 3s is U-shaped.
  • the second core portion 3s is a molded body in which the second end core piece 33s, the first side core piece 321s, and the second side core piece 322s are integrally formed.
  • the length L3s of the second end core piece 33s along the first direction D1 is shorter than the length L3f of the first end core piece 33f along the first direction D1.
  • the length L3s is preferably ⁇ the length L3f ⁇ (saturation magnetic flux density Bf of the first core portion 3f / saturation magnetic flux density Bs of the second core portion 3s) ⁇ or more, as in the first embodiment.
  • the length L21s and the length L22s of the present embodiment are the same as the length L21s and the length L22s of the first embodiment, respectively, and the length L21f and the length L22f of the present embodiment are the same. Shorter than.
  • the length L21s and the length L22s are twice or less the length L3s as in the first embodiment.
  • the second core portion 3s is made of a powder compact as in the first embodiment.
  • the first core portion 3f and the second core portion 3s are in contact with the end face of the first side core piece 321f of the first core portion 3f and the end face of the first side core piece 321s of the second core portion 3s, and the first core portion 3f
  • the end face of the second side core piece 322f and the end face of the second side core piece 322s of the second core portion 3s are combined so as to be in contact with each other.
  • the magnitude relation of the saturation magnetic flux density of the first core portion 3f and the second core portion 3s, the magnitude relation of the relative magnetic permeability, the magnitude relation of the iron loss, and the magnitude relation of the thermal conductivity are the same as those in the first embodiment.
  • the gap portion 3g is composed of a part of a mold resin portion (not shown). Unlike the first embodiment, the gap portion 3g is arranged between the end face of the first middle core piece 31f and the end face of the second end core piece 33s, and is outside the winding portion 21.
  • the length Lg of the gap portion 3g along the first direction D1 is 2 mm or less as in the first embodiment.
  • the reactor 1 of the present embodiment can easily adjust the inductance and heat dissipation without increasing the size.
  • the gap portion 3g is arranged outside the winding portion 21, the effect of reducing the eddy current loss due to the reduction of the leakage flux is lower than that of the reactor 1 of the first embodiment.
  • Embodiment 5 >> [Reactor]
  • the reactor 1 of the fifth embodiment will be described with reference to FIGS. 7 to 9.
  • the reactor 1 of the present embodiment has a point that the coil 2 has two winding portions 21 and 22, and a point that the combination of the first core portion 3f and the second core portion 3s is a UU type. It is different from Reactor 1.
  • the coil 2 has two rectangular tubular winding portions 21 and 22. Since the reactor 1 of the present embodiment has two winding portions 21 and 22, the winding portions have the same cross-sectional area and the same number of turns as compared with the reactor 1 having one winding portion 21 of the first embodiment. In this case, the length of the winding portions 21 and 22 along the axial direction can be shortened. In this embodiment, the winding portions 21 and 22 are configured by spirally winding separate windings. Each winding is as described above.
  • the two winding portions 21 and 22 can be electrically connected as follows, for example.
  • the connecting member 23 independent of the two winding portions 21 and 22 is connected to the conductor of the winding in the two winding portions 21 and 22.
  • the connecting member 23 is composed of, for example, the same member as the winding.
  • the conductors of the windings in the two winding portions 21 and 22 are directly connected to each other.
  • the end side of the winding in one winding portion 21 may be bent and stretched to the end side of the winding in the other winding portion 22.
  • the connection between the conductor and the connecting member 23 and the connection between the conductors can be performed by welding or pressure welding.
  • the two winding portions 21 and 22 may be configured by spirally winding one winding having no joint. In that case, the two winding portions 21 and 22 are electrically connected via a connecting portion formed by bending a part of the winding in a U shape on one end side in the axial direction of the coil 2.
  • the above-mentioned external device is connected to the exposed conductor wire at one ends 21a and 22a of the winding portions 21 and 22.
  • the above-mentioned connecting member 23 is connected to the exposed conductor wire.
  • the magnetic core 3 of the present embodiment has a first end core piece 33f and a second end core piece 33s, and a first middle core portion 311 and a second middle core portion 312.
  • the direction along the axial direction of the winding portion 21 is the first direction D1
  • the parallel direction of the first middle core portion 311 and the second middle core portion 312 is the second direction D2
  • the first direction D1 and the second direction is defined as the third direction D3.
  • the first end core piece 33f faces both one end of one winding portion 21 and one end of the other winding portion 21.
  • the second end core piece 33s faces both the other end of one winding 21 and the other end of the other winding 21.
  • the first middle core portion 311 has a portion arranged inside one of the winding portions 21.
  • the second middle core portion 312 has a portion arranged inside the other winding portion 21.
  • the shape of the first middle core portion 311 and the second middle core portion 312 is a square columnar shape.
  • the length of the first middle core portion 311 along the first direction D1 and the length of the second middle core portion 312 along the first direction D1 are the same as each other.
  • the length of the first middle core portion 311 along the first direction D1 and the length of the second middle core portion 312 along the first direction D1 are equivalent to the length along the axial direction of the winding portion 21.
  • the length of the first middle core portion 311 along the first direction D1 and the length of the second middle core portion 312 along the first direction D1 include the length Lg of the gap portion 3g described later along the first direction D1. Not included.
  • the length of the first middle core portion 311 along the first direction D1 is the total length (L11f + L11s) of the length L11f of the first middle core piece 311f and the length L11s of the first middle core piece 311s, which will be described later.
  • the length of the second middle core portion 312 along the first direction D1 is the total length (L12f + L12s) of the length L12f of the second middle core piece 312f and the length L12s of the second middle core piece 312s, which will be described later.
  • the first middle core portion 311 may be composed of two core pieces, a first middle core piece 311f and a first middle core piece 311s, as in the present embodiment or the eighth embodiment described later with reference to FIG. Further, the first middle core portion 311 may be composed of one first middle core piece 311f as in the sixth and seventh embodiments described later with reference to FIGS. 10 and 11, respectively.
  • the second middle core portion 312 is composed of two core pieces, a second middle core piece 312f and a second middle core piece 312s, as in the seventh and eighth embodiments described later with reference to this embodiment and FIGS. 11 and 12, respectively. May occur. Further, the second middle core portion 312 may be composed of one second middle core piece 312f as in the sixth embodiment described later with reference to FIG. 10.
  • the combination of the first core portion 3f and the second core portion 3s is a UU type in this embodiment. Further, the above combination may be a U-I type as in the sixth embodiment. Further, the above combination may be a JL type as in the seventh embodiment. Then, the above combination may be a JJ type as in the eighth embodiment. In addition, although not shown, the above combination may be an LL type. These combinations make it easier to adjust the inductance and heat dissipation. Further, since the reactor 1 can be constructed by combining the first core portion 3f and the second core portion 3s with respect to the winding portion 21 along the axial direction of the winding portion 21, the reactor 1 is excellent in manufacturing workability.
  • the first core portion 3f has at least one selected from the group consisting of at least a part of the first middle core portion 311 and at least a part of the second middle core portion 312 in addition to the first end core piece 33f. Can be mentioned.
  • the shape of the first core portion 3f is L. It is in the shape of a letter.
  • the shape of the first core portion 3f is U-shaped. Shaped or J-shaped.
  • the shape of the first core portion 3f is U-shaped.
  • the shape of the first core portion 3f is J-shaped.
  • the shape of the first core portion 3f of this embodiment is U-shaped. That is, the first core portion 3f of the present embodiment has a first end core piece 33f, at least a part of the first middle core portion 311 and at least a part of the second middle core portion 312. Specifically, the first core portion 3f of the present embodiment includes a first end core piece 33f, a part of the first middle core portion 311 and a part of the second middle core portion 312. More specifically, the first core portion 3f of the present embodiment has a first end core piece 33f, a first middle core piece 311f, and a second middle core piece 312f.
  • the first core portion 3f is a molded body in which the first end core piece 33f, the first middle core piece 311f, and the second middle core piece 312f are integrated.
  • the first end core piece 33f connects the first middle core piece 311f and the second middle core piece 312f.
  • the first middle core piece 311f and the second middle core piece 312f are provided at both ends of the first end core piece 33f.
  • the first core portion 3f is composed of a molded body of a composite material as in the first embodiment.
  • the second core portion 3s may be composed of only the second end core piece 33s, or in addition to the second end core piece 33s, depending on the combination of the first core portion 3f and the second core portion 3s. It may have at least one selected from the group consisting of the rest of the middle core portion 311 and the rest of the second middle core portion 312.
  • the shape of the second core portion 3s is I-shaped.
  • the shape of the second core portion 3s is L-shaped.
  • the second core part 3s When the second end core piece 33s, the remaining portion of the first middle core portion 311 and the remaining portion of the second middle core portion 312 are provided, the shape of the second core portion 3s is U-shaped or J-shaped.
  • the shape of the second core portion 3s of this embodiment is U-shaped. That is, the second core portion 3s of the present embodiment has a second end core piece 33s, a remaining portion of the first middle core portion 311 and a remaining portion of the second middle core portion 312. Specifically, the second core portion 3s has a second end core piece 33s, a first middle core piece 311s, and a second middle core piece 312s.
  • the second core portion 3s is a molded body in which the second end core piece 33s, the first middle core piece 311s, and the second middle core piece 312s are integrated.
  • the second end core piece 33s connects the first middle core piece 311s and the second middle core piece 312s.
  • the first middle core piece 311s and the second middle core piece 312s are provided at both ends of the second end core piece 33s.
  • the second core portion 3s is composed of a powder compact as in the first embodiment.
  • the size of the first core portion 3f and the size of the second core portion 3s are different. Specifically, there is a portion in which the length of each core piece of the first core portion 3f along the first direction D1 and the length of each core piece of the second core portion 3s along the first direction D1 are different.
  • the length of each core piece of the first core portion 3f along the second direction D2, the length along the third direction D3, the length of each core piece of the second core portion 3s along the second direction D2, and the first The lengths along the three directions D3 are the same as each other.
  • the length L11f of the first middle core piece 311f along the first direction D1 and the length L12f of the second middle core piece 312f along the first direction D1 are the same.
  • the length L11s of the first middle core piece 311s along the first direction D1 and the length L12s of the second middle core piece 312s along the first direction D1 are the same.
  • the length L11f and the length L11s may be different as in the present embodiment, or may be the same as in the present embodiment.
  • the length L12f and the length L12s may be different as in the present embodiment, or may be the same as in the present embodiment.
  • the length L11f and the length L12f are each longer than the length L11s and the length L12s, respectively.
  • the length along the second direction D2 and the length along the second direction D2 of the second middle core piece 312s are the same as each other as described above.
  • the length along the third direction D3 and the length along the third direction D3 of the second middle core piece 312s are the same as each other as described above.
  • the length L3s of the second end core piece 33s along the first direction D1 is shorter than the length L3f of the first end core piece 33f along the first direction D1.
  • the length L3s is preferably ⁇ the length L3f ⁇ (saturation magnetic flux density Bf of the first core portion 3f / saturation magnetic flux density Bs of the second core portion 3s) ⁇ or more, as in the first embodiment.
  • the length of the first end core piece 33f along the second direction D2 and the length of the second end core piece 33s along the second direction D2 are the same as each other.
  • the length of the first end core piece 33f along the third direction D3 and the length of the second end core piece 33s along the third direction D3 are the same as each other.
  • the second core portion 3s is composed of a dust compact. That is, as described above, the length L11s and the length L12s may be twice or less or more than twice the length L3s. The reason is the same as the reason described in the first embodiment. Suitable magnifications of the length L11s and the length L12s with respect to the length L3s are the same as described above. In this embodiment, the length L11s and the length L12s are twice or less the length L3s.
  • the first core portion 3f and the second core portion 3s are formed between the end face of the first middle core piece 311f of the first core portion 3f and the end face of the first middle core piece 311s of the second core portion 3s. It is combined so as to provide a gap between the end face of the second middle core piece 312f of the first core portion 3f and the end face of the second middle core piece 312s of the second core portion 3s.
  • the length along the first direction D1 of each interval corresponds to the length Lg along the first direction D1 of the gap portion 3g.
  • the first core portion 3f and the second core portion 3s are in contact with the end face of the first middle core piece 311f of the first core portion 3f and the end face of the first middle core piece 311s of the second core portion 3s, and the first core portion 3f
  • the end face of the second middle core piece 312f and the end face of the second middle core piece 312s of the second core portion 3s may be combined so as to be in contact with each other.
  • the magnitude relation of the saturation magnetic flux density of the first core portion 3f and the second core portion 3s, the magnitude relation of the relative magnetic permeability, the magnitude relation of the iron loss, and the magnitude relation of the thermal conductivity are the same as those in the first embodiment.
  • the gap portion 3g is composed of a part of a mold resin portion (not shown). The location of the gap portion 3g is inside the coil 2 as in the first embodiment. Specifically, the gap portion 3g is arranged between the end face of the first middle core piece 311f inside the winding portion 21 and the end face of the first middle core piece 311s, and the second middle core inside the winding portion 22. It is between the end face of the piece 312f and the end face of the second middle core piece 312s.
  • the total length Lg of the gap portion 3g is 2 mm or less as in the first embodiment. That is, the total of the length Lg of the gap portion 3g inside the winding portion 21 and the length Lg of the gap portion 3g inside the winding portion 22 is 2 mm or less.
  • the reactor 1 of the present embodiment can easily adjust the inductance and heat dissipation without increasing the size.
  • Embodiment 6 The reactor 1 of the sixth embodiment will be described with reference to FIG.
  • the reactor 1 of the present embodiment is different from the fifth embodiment in that the combination of the first core portion 3f and the second core portion 3s is a U-I type.
  • the following description will focus on the differences from the fifth embodiment.
  • the description of the configuration similar to that of the fifth embodiment may be omitted.
  • These points are the same in the seventh and eighth embodiments described later.
  • the mold resin portion is omitted for convenience of explanation. This point is the same in FIGS. 11 and 12, which are referred to in the seventh and eighth embodiments described later, respectively.
  • the magnetic core 3 has the same first end core piece 33f and second end core piece 33s as in the fifth embodiment. Further, the magnetic core 3 has a first middle core portion 311 and a second middle core portion 312 different from those in the fifth embodiment. The first middle core portion 311 and the second middle core portion 312 are composed of one first middle core piece 311f and a second middle core piece 312f, respectively.
  • the shape of the first core portion 3f is U-shaped.
  • the first core portion 3f is a molded body in which the first end core piece 33f, the first middle core portion 311 and the second middle core portion 312 are integrated. That is, the first core portion 3f is composed of a first end core piece 33f, a first middle core piece 311f, and a second middle core piece 312f.
  • the length L11f of the first middle core piece 311f along the first direction D1 and the length L12f of the second middle core piece 312f along the first direction D1 are the same.
  • the L11f and the L12f of the present embodiment are longer than the length L11f and the length L12f of the first embodiment, respectively.
  • the first core portion 3f is composed of a molded body of a composite material as in the fifth embodiment.
  • the shape of the second core portion 3s is I-shaped.
  • the second core portion 3s is composed of a second end core piece 33s.
  • the length L3s of the second end core piece 33s along the first direction D1 is shorter than the length L3f of the first end core piece 33f along the first direction D1.
  • the length L3s is preferably ⁇ the length L3f ⁇ (saturation magnetic flux density Bf of the first core portion 3f / saturation magnetic flux density Bs of the second core portion 3s) ⁇ or more, as in the fifth embodiment.
  • the second core portion 3s is made of a powder compact as in the fifth embodiment.
  • the first core portion 3f and the second core portion 3s are the end face of the first middle core piece 311f and the end face of the second middle core piece 312f of the first core portion 3f, and the second end core piece 33s of the second core portion 3s. It is combined so that there is a gap between it and the end face of. Each interval is equal to each other.
  • the magnitude relation of the saturation magnetic flux density of the first core portion 3f and the second core portion 3s, the magnitude relation of the relative magnetic permeability, the magnitude relation of the iron loss, and the magnitude relation of the thermal conductivity are the same as those in the fifth embodiment.
  • the gap portion 3g is composed of a part of a mold resin portion (not shown). Unlike the fifth embodiment, the gap portion 3g is arranged outside the winding portions 21 and 22. Specifically, the gap portion 3g is arranged between the end face of the first middle core piece 311f and the end face of the second end core piece 33s, and between the end face of the second middle core piece 312f and the end face of the second end core piece 33s. Between. The total length Lg of the gap portion 3g along the first direction D1 is 2 mm or less as in the fifth embodiment.
  • the reactor 1 of the present embodiment can easily adjust the inductance and heat dissipation without increasing the size.
  • the gap portion 3g is arranged outside the winding portions 21 and 22, the effect of reducing the eddy current loss due to the reduction of the leakage flux is lower than that of the reactor 1 of the fifth embodiment.
  • the density distribution of the second core portion 3s is more unlikely to occur as compared with the reactor 1 of the fifth embodiment. This is because the second core portion 3s is composed of only the second end core piece 33s, so that the pressure at the time of molding the second core portion 3s is unlikely to vary.
  • Embodiment 7 >> [Reactor]
  • the reactor 1 of the seventh embodiment will be described with reference to FIG.
  • the reactor 1 of the present embodiment is different from the fifth embodiment in that the combination of the first core portion 3f and the second core portion 3s is a JL type.
  • the magnetic core 3 has the same first end core piece 33f and second end core piece 33s as in the fifth embodiment. Further, the magnetic core 3 has a first middle core portion 311 and a second middle core portion 312 different from those in the fifth embodiment.
  • the first middle core portion 311 is composed of one first middle core piece 311f.
  • the second middle core portion 312 is composed of two core pieces, a second middle core piece 312f and a second middle core piece 312s.
  • the length L11f of the first middle core portion 311 along the first direction D1 and the length of the second middle core portion 312 along the first direction D1 (L12f + L12s) are the same.
  • the shape of the first core portion 3f is J-shaped.
  • the first core portion 3f is a molded body in which the first end core piece 33f, the first middle core portion 311 and the second middle core piece 312f are integrally formed. That is, the first core portion 3f is composed of a first end core piece 33f, a first middle core piece 311f, and a second middle core piece 312f.
  • the length L11f of the first middle core piece 311f along the first direction D1 is the length L12f of the second middle core piece 312f along the first direction D1 and the first of the second middle core pieces 312s in the second core portion 3s. It is the same as the total length with the length L12s along the direction D1. That is, the length L11f is longer than each of the length L12f and the length L12s. The length L11f is longer than the length L11f of the fifth embodiment. The length L12f is the same as the length L12f of the fifth embodiment.
  • the first core portion 3f is composed of a molded body of a composite material as in the fifth embodiment.
  • the shape of the second core portion 3s is L-shaped.
  • the second core portion 3s is a molded body in which the second end core piece 33s and the second middle core piece 312s are integrally formed.
  • the length L3s of the second end core piece 33s along the first direction D1 is shorter than the length L3f of the first end core piece 33f along the first direction D1.
  • the length L3s is preferably ⁇ the length L3f ⁇ (saturation magnetic flux density Bf of the first core portion 3f / saturation magnetic flux density Bs of the second core portion 3s) ⁇ or more, as in the first embodiment.
  • the length L12s is shorter than the length L12f.
  • the length L12s is the same as the length L12s of the fifth embodiment.
  • the length L12s is twice or less the length L3s as in the fifth embodiment.
  • the second core portion 3s is made of a powder compact as in the first embodiment.
  • the first core portion 3f and the second core portion 3s are formed between the end face of the first middle core piece 311f of the first core portion 3f and the end face of the second end core piece 33s of the second core portion 3s, and the first core portion. It is combined so as to provide a gap between the end face of the second middle core piece 312f of 3f and the end face of the second middle core piece 312s of the second core portion. Each interval is equal to each other.
  • the magnitude relation of the saturation magnetic flux density of the first core portion 3f and the second core portion 3s, the magnitude relation of the relative magnetic permeability, the magnitude relation of the iron loss, and the magnitude relation of the thermal conductivity are the same as those in the fifth embodiment.
  • the gap portion 3g is composed of a part of a mold resin portion (not shown). Unlike the fifth embodiment, the gap portion 3g is arranged outside the winding portion 21 and inside the winding portion 22. Specifically, the gap portion 3g is arranged between the end face of the first middle core piece 311f and the end face of the second end core piece 33s, and between the end face of the second middle core piece 312f and the end face of the second middle core piece 312s. Between. The total length Lg of the gap portion 3g along the first direction D1 is 2 mm or less as in the fifth embodiment.
  • the reactor 1 of the present embodiment can easily adjust the inductance and heat dissipation without increasing the size.
  • the effect of reducing the eddy current loss due to the reduction of the leakage flux is lower than that of the reactor 1 of the fifth embodiment.
  • Embodiment 8 >> [Reactor]
  • the reactor 1 of the eighth embodiment will be described with reference to FIG.
  • the reactor 1 of the present embodiment is different from the fifth embodiment in that the combination of the first core portion 3f and the second core portion 3s is a JJ type.
  • the magnetic core 3 has the same first end core piece 33f and second end core piece 33s as in the fifth embodiment. Further, the magnetic core 3 has a first middle core portion 311 and a second middle core portion 312 different from those in the fifth embodiment.
  • the first middle core portion 311 is composed of two core pieces, a first middle core piece 311f and a first middle core piece 311s.
  • the second middle core portion 312 is composed of two core pieces, a second middle core piece 312f and a second middle core piece 312s.
  • the length of the first middle core portion 311 along the first direction D1 (L11f + L11s) and the length of the second middle core portion 312 along the first direction D1 (L12f + L12s) are the same.
  • the shape of the first core portion 3f is J-shaped.
  • the first core portion 3f is a molded body in which the first end core piece 33f, the first middle core piece 311f, and the second middle core piece 312f are integrated.
  • the length L11f of the first middle core piece 311f along the first direction D1 is longer than the length L12f of the second middle core piece 312f along the first direction D1.
  • the first core portion 3f is composed of a molded body of a composite material as in the fifth embodiment.
  • the shape of the second core portion 3s is J-shaped.
  • the second core portion 3s is a molded body in which the second end core piece 33s, the first middle core piece 311s, and the second middle core piece 312s are integrally formed.
  • the length L3s of the second end core piece 33s along the first direction D1 is shorter than the length L3f of the first end core piece 33f along the first direction D1.
  • the length L3s is preferably ⁇ the length L3f ⁇ (saturation magnetic flux density Bf of the first core portion 3f / saturation magnetic flux density Bs of the second core portion 3s) ⁇ or more, as in the first embodiment.
  • the length L11s of the first middle core piece 311s along the first direction D1 is shorter than the length L12s of the second middle core piece 312s along the first direction D1.
  • the length L11s is shorter than the length L11f.
  • the length L12s is shorter than the length L12f.
  • the length L11s and the length L12s are each twice or less the length L3s.
  • the second core portion 3s is made of a powder compact as in the first embodiment.
  • the first core portion 3f and the second core portion 3s are between the end face of the first middle core piece 311f of the first core portion 3f and the end face of the first middle core piece 311s of the second core portion 3s, and the first core portion. It is combined so as to provide a gap between the end face of the second middle core piece 312f of 3f and the end face of the second middle core piece 312s of the second core portion 3s. Each interval is equal to each other.
  • the magnitude relation of the saturation magnetic flux density of the first core portion 3f and the second core portion 3s, the magnitude relation of the relative magnetic permeability, the magnitude relation of the iron loss, and the magnitude relation of the thermal conductivity are the same as those in the fifth embodiment.
  • the gap portion 3g is composed of a part of a mold resin portion (not shown).
  • the location of the gap portion 3g is the inside of each of the winding portions 21 and 22 as in the fifth embodiment.
  • the gap portion 3g is arranged between the end face of the first middle core piece 311f and the end face of the first middle core piece 311s, and between the end face of the second middle core piece 312f and the end face of the second middle core piece 312s. Between.
  • the total length Lg of the gap portion 3g along the first direction D1 is 2 mm or less as in the fifth embodiment.
  • the reactor 1 of the present embodiment can easily adjust the inductance and heat dissipation without increasing the size.
  • Embodiment 9 [Converter / Power converter]
  • the reactor 1 of the first to eighth embodiments can be used for applications that satisfy the following energization conditions.
  • the energization conditions include a maximum direct current of 100 A or more and 1000 A or less, an average voltage of 100 V or more and 1000 V or less, and an operating frequency of 5 kHz or more and 100 kHz or less.
  • the reactor 1 of the first to eighth embodiments can be typically used as a component of a converter mounted on a vehicle such as an electric vehicle or a hybrid vehicle, or as a component of a power conversion device including the converter.
  • a vehicle 1200 such as a hybrid vehicle or an electric vehicle is driven by a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and power supplied from the main battery 1210, and is used for traveling.
  • the motor 1220 is provided.
  • the motor 1220 is typically a three-phase AC motor that drives the wheels 1250 during travel and functions as a generator during regeneration.
  • the vehicle 1200 includes an engine 1300 in addition to the motor 1220.
  • an inlet is shown as a charging point of the vehicle 1200, but it may be provided with a plug.
  • the power conversion device 1100 has a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 to perform mutual conversion between direct current and alternating current.
  • the converter 1110 shown in this example boosts the input voltage of the main battery 1210 of about 200 V or more and 300 V or less to about 400 V or more and 700 V or less when the vehicle 1200 is running, and supplies power to the inverter 1120.
  • the converter 1110 lowers the input voltage output from the motor 1220 via the inverter 1120 to a DC voltage suitable for the main battery 1210, and charges the main battery 1210.
  • the input voltage is a DC voltage.
  • the inverter 1120 converts the direct current boosted by the converter 1110 into a predetermined alternating current and supplies power to the motor 1220 when the vehicle 1200 is running, and converts the alternating current output from the motor 1220 into a direct current during regeneration and outputs it to the converter 1110. doing.
  • the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor 1115, and converts the input voltage by repeating ON / OFF.
  • the conversion of the input voltage is performed here by raising and lowering the pressure.
  • Power devices such as field effect transistors and insulated gate bipolar transistors are used for the switching element 1111.
  • the reactor 1115 has a function of smoothing the change when the current tries to increase or decrease due to the switching operation by utilizing the property of the coil which tries to prevent the change of the current flowing in the circuit.
  • the reactor 1 according to any one of the first to eighth embodiments is provided. By providing the reactor 1 and the like, which are excellent in heat dissipation without increasing the size, the power conversion device 1100 and the converter 1110 can be expected to be downsized and improved in heat dissipation.
  • the vehicle 1200 is connected to the converter 1110, the converter 1150 for a power supply device connected to the main battery 1210, the sub-battery 1230 and the main battery 1210 which are the power sources of the accessories 1240, and applies the high voltage of the main battery 1210.
  • a converter 1160 for auxiliary power supply that converts to low voltage is provided.
  • the converter 1110 typically performs DC-DC conversion, but the power supply converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Some converters 1150 for power feeding devices perform DC-DC conversion.
  • the reactor of the converter 1150 for the power supply device and the converter 1160 for the auxiliary power supply has the same configuration as the reactor 1 of any one of the first to eighth embodiments, and the reactor whose size and shape are appropriately changed can be used. .. Further, a reactor 1 or the like according to any one of the first to eighth embodiments can be used as a converter that converts input power and performs only step-up or only step-down.
  • the length of the second core portion 3s along the second direction D2 of the second end core piece 33s is the second length of the first core portion 3f of the first end core piece 33f. It may be shorter than the length along the direction D2.
  • the length of the second core portion 3s along the second direction D2 of the second end core piece 33s may be about the same as the length of the winding portion 21 along the second direction D2.
  • the length of the first core portion 3f in the first side core piece 321f and the second side core piece 322f along the first direction D1 is the side surface of the first side core piece 321f and the second side core piece 322f and the side surface of the second end core piece 33s.
  • the length is such that they face each other.
  • the lengths of the first side core piece 321f and the second side core piece 322f along the first direction D1 are the windings of the end faces of the first side core piece 321f and the second side core piece 322f and the second end core piece 33s.
  • the length is such that the end face on the side opposite to the turning portion 21 side is substantially flush with the end face.

Abstract

La présente invention concerne un réacteur comprenant une bobine et un noyau magnétique, la bobine ayant une partie enroulée cylindrique, le noyau magnétique étant un ensemble obtenu par combinaison d'une première partie de noyau et d'une seconde partie de noyau, la première partie de noyau ayant une première pièce de noyau d'extrémité faisant face à une surface d'extrémité de la partie enroulée, la seconde partie de noyau ayant une seconde pièce de noyau d'extrémité faisant face à l'autre surface d'extrémité de la partie enroulée, la densité de flux magnétique de saturation de la seconde partie de noyau étant supérieure à celle de la première partie de noyau, la longueur L3s de la seconde pièce de noyau d'extrémité étant inférieure à la longueur L3f de la première pièce de noyau d'extrémité, la longueur L3s de la seconde pièce de noyau d'extrémité étant une longueur dans la seconde pièce de noyau d'extrémité le long de la direction axiale de la partie enroulée, et la longueur L3f de la première pièce de noyau d'extrémité étant une longueur dans la première pièce de noyau d'extrémité le long de la direction axiale de la partie enroulée.
PCT/JP2021/007537 2020-03-02 2021-02-26 Réacteur, convertisseur et dispositif de conversion de puissance WO2021177190A1 (fr)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0613243A (ja) * 1992-06-25 1994-01-21 Sony Corp コア構体
JP2000294429A (ja) * 1999-04-09 2000-10-20 Hitachi Ferrite Electronics Ltd 複合磁芯
JP2013143454A (ja) * 2012-01-10 2013-07-22 Sumitomo Electric Ind Ltd リアクトル、コア部品、リアクトルの製造方法、コンバータ、及び電力変換装置

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0613243A (ja) * 1992-06-25 1994-01-21 Sony Corp コア構体
JP2000294429A (ja) * 1999-04-09 2000-10-20 Hitachi Ferrite Electronics Ltd 複合磁芯
JP2013143454A (ja) * 2012-01-10 2013-07-22 Sumitomo Electric Ind Ltd リアクトル、コア部品、リアクトルの製造方法、コンバータ、及び電力変換装置

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