Source: https://patents.google.com/patent/JP2007180140A/en
Timestamp: 2020-01-24 15:24:28
Document Index: 436130157

Matched Legal Cases: ['art 5', 'art 6', 'art 6', 'art 6', 'art 5', 'arts 5', 'arts 5', 'arts 5', 'art 10', 'art 11', 'arts 5', 'art 17', 'art 17', 'art 11', 'art 10', 'art 10', 'art 11', 'art 6', 'art 6', 'art 6', 'art 7', 'art 10', 'art 11']

JP2007180140A - Magnetic component - Google Patents
JP2007180140A
JP2007180140A JP2005374543A JP2005374543A JP2007180140A JP 2007180140 A JP2007180140 A JP 2007180140A JP 2005374543 A JP2005374543 A JP 2005374543A JP 2005374543 A JP2005374543 A JP 2005374543A JP 2007180140 A JP2007180140 A JP 2007180140A
JP2005374543A
武 立石
2005-12-27 Application filed by Denso Corp, 株式会社デンソー filed Critical Denso Corp
2005-12-27 Priority to JP2005374543A priority Critical patent/JP2007180140A/en
2007-07-12 Publication of JP2007180140A publication Critical patent/JP2007180140A/en
<P>PROBLEM TO BE SOLVED: To provide a compact magnetic component while reducing the vibration of a reactor. <P>SOLUTION: One of two magnetic connection sections 6 of the core of the reactor 1 is fastened to a bottom plate 21e of a metal case 21, and the other of the two magnetic connection section 6 is not fixed to the metal case 21 as a free end, thus stretching the magnetic connection section 6 of the free end side freely in the direction of the magnetic path of a post section in the core due to a change in the amount of magnetic flux and hence preventing a spacer that is interposed at the gap between the cores and adheres to the end face of the cores from being peeled from the end face of the cores. <P>COPYRIGHT: (C)2007,JPO&INPIT
The present invention relates to a magnetic component formed by winding a coil around a soft magnetic core. Here, the magnetic component includes both a reactor having one type of coil and a transformer having a plurality of types of coils. However, a reactor normally has a gap for preventing magnetic saturation in a magnetic path, but a transformer is required to minimize the gap.
For example, in a power electronic circuit device such as a vehicle DCDC converter described in Patent Document 1 below, magnetic components such as a reactor and a transformer are widely used for applications such as current smoothing and input / output electrical insulation. A choke coil having a soft magnetic core is the same as a reactor. The DC-DC converter essentially requires high-speed switching, and superimposes a high-frequency switching noise voltage on the input voltage or output voltage. However, fluctuations in the voltage of the battery, which is a vehicle power supply, adversely affect its life. Therefore, in a DC / DC converter for a vehicle, a smoothing reactor that smoothes the input power or output power is an essential component. A DC / DC converter for a vehicle equipped with this type of reactor (including a choke coil with a core) is described in, for example, the following Patent Document 1 proposed by the present applicant.
As a reactor used in a power range (several tens of watts to several tens of kW) applied to this type of vehicle power electronic circuit device, a dry reactor that is not immersed in oil is common. The most common type of this dry reactor is the columnar core having two pillars parallel to each other and two beams that magnetically connect the ends of these pillars. Coiled. As another modified form, there is also known a Japanese character core in which one column portion is further added in parallel with the two column portions of the square core and the central column portion is a common magnetic path. Since these square-shaped cores and date-shaped cores have a square core shape, they are also referred to as square cores hereinafter. In addition, a sealed core having a peripheral wall-shaped column portion around a central column portion around which a coil is wound is known. Since this core has a short cylindrical shape or a thick disk shape, it is also referred to as a disk-shaped core hereinafter. A magnetic part having a disk-shaped core has the advantage that the electromagnetic noise is reduced because the coil is surrounded by the peripheral wall-shaped column part, and the coil length can be shortened, compared with the magnetic part having a square core. Usually, there is a disadvantage that the idle space is large in the case of the power electronic circuit device having a rectangular shape.
In magnetic parts, it is known that a stretching force acts on the core in the direction of magnetic flux. In other words, in a rectangular core having a plurality of column portions that are wound around a coil and extending in parallel and a beam portion that connects both ends of the column portion, the magnetic flux changes in the respective magnetic path directions in the column portion and the beam portion. Accordingly, the expansion / contraction force, in other words, the vibration force acts to vibrate the column portion and the beam portion. This vibration is widely known as magnetic vibration.
It is also widely practiced to house magnetic parts in a metal square case. This rectangular case has a mechanical protection effect and an electromagnetic noise reduction effect. Hereinafter, the magnetic component built in the rectangular case is also referred to as a case built-in magnetic component. In a case built-in type magnetic component, it is usual to fasten a portion where a core coil is not wound to, for example, a bottom plate of the case. Usually, the bottom plate of the case to which the core is fastened also serves as a heat radiating member that radiates the heat of the core.
The core constituting the magnetic closed circuit interlinking with the coil is configured by combining a plurality of partial cores for coil insertion or the like. That is, the core of the magnetic component has a split core structure. For this reason, a gap is generated between the end faces of the two partial cores facing each other. In order to prevent magnetic saturation, the width of the gap is positively increased in the reactor. A nonmagnetic spacer is usually inserted into this gap. Often, three or more partial cores are combined to form a magnetic component core. For this reason, fixing each partial core which comprises a core to a case (for example, the baseplate) by fastening, welding, etc. is performed, respectively.
When each partial core is fastened to the bottom plate of the case, the gap (interval) changes due to the temperature rise of the core having a coefficient of thermal expansion different from that of the case, and the inductance value of the magnetic component changes. Problems such as increased magnetic vibration transmission and increased release of magnetic noise to the outside, and strong mechanical stress on the partial core due to the magnetic vibration and thermal expansion occur.
In order to improve this problem, the following Patent Document 2 discloses that a pair of beam portions on both sides of a core pillar portion (coil winding portion) are parallel to the main surface of the bottom plate with respect to the bottom plate of the case. We propose a structure that supports displacement in various directions, especially in the gap width direction. As this support structure, for example, a method is proposed in which both ends are extended in the magnetic path direction of the beam portion on the upper surface of the beam portion of the core by a spring steel pressing plate fixed to the bottom plate of the case.
JP 2000-014149 A JP 2004-241475 A
However, the above-described core support structure of Patent Document 1 has the function of mechanically supporting the core on the bottom plate of the case while allowing the core to move relative to the bottom plate of the case in the surface direction of the bottom plate. It is realized by the force to press against. That is, if the force applied to the core is smaller than the frictional force of the core against the bottom plate of the case, the core remains stationary with respect to the bottom plate of the case, and the force applied to the core is the frictional force of the core against the bottom plate of the case. If it is larger, the core is displaced relative to the bottom plate of the case. Therefore, it is difficult to adjust the force for pressing the core against the bottom plate of the case. In particular, it is necessary to adjust the force with which the core is pressed against the bottom plate of the case with two beam portions at both ends of the core column portion, which complicates the work.
In addition, when the magnetic component is a reactor, adopting a both-end support structure that fastens both ends of the core pillar portion around which the coil is wound to the case, the core pillar portion is displaced in the reduction direction due to a change in the amount of magnetic flux. The nonmagnetic spacer for preventing magnetic saturation interposed between the pillars and the end face of the core pillar part peel off, and the AC current after peeling causes the nonmagnetic spacer and the end face of the core pillar part to move at high speed. There was a problem that a large noise was generated by collision.
The present invention has been made in view of the above problems, and its object is to provide a magnetic component that reduces vibrations by reducing stress applied to the core during assembly or during AC energization to the core by a simple mechanism. It is said.
The magnetic component of the present invention made to solve the above problems includes at least two column portions parallel to each other, a magnetic coupling portion on one end side that magnetically connects one end portions of the column portions, and A soft magnetic core that forms a closed magnetic circuit having a magnetic coupling portion on the other end side that magnetically connects the other end portions, a coil wound around the column portion, and the core are fastened. A square box-like case that accommodates the core and the coil, and the column part is a magnetic component that expands and contracts in the magnetic path direction of the column part by alternating current conduction to the coil. A guide portion that is fixed to the case and holds one of the two magnetic coupling portions so as to be displaceable in the magnetic path direction of the column portion; the other of the two magnetic coupling portions is fixed to the case; It is characterized by. The core is preferably formed in a substantially square shape to form a so-called square core. The square core referred to in the present specification refers to a core having a substantially flat outer surface on which a column portion around which a coil is wound. Of course, the boundary between the two substantially flat outer surfaces of the square core may be chamfered and curved.
That is, the present invention is arranged at a substantially right angle with the plurality of pillar portions of the core, and only one of the pair of magnetic coupling portions that couple the end portions on the same side of the two pillar portions is fixed to the case, The other of the pair of magnetic path directions is essentially a free end. However, the magnetic coupling portion serving as a free end is held so as to be displaceable in the magnetic path direction of the column portion by a guide portion fixed to the case.
In this way, adjustment of the frictional force between the two magnetic coupling portions of the core and the case is essentially unnecessary as compared with the core support structure described in Patent Document 1 described above. Simplification is possible. In addition, compared to the case where the boundary portions between the total of the four column portions and the magnetic coupling portions are fixed to the case, the core is caused by a mechanical force such as a difference in thermal expansion coefficient between the case and the core and magnetic vibration of the core. In addition, no strong stress is applied to the case, and changes in the magnetic properties of the core due to this stress can be prevented. Also, the core assembling work is simplified.
More specifically, since the magnetic vibration of the core is one end in the magnetic path direction of the core, that is, one of the two magnetic coupling portions is a free end, the vibration energy of the magnetic component is applied to the case that is the outer member that wraps the core. It is rarely transmitted. Therefore, it is possible to satisfactorily reduce the vibration of the case due to the received vibration energy.
Note that each of the pillar portions may be a single member, or a member integrated with the magnetic coupling portion, or may be configured by combining a plurality of partial cores in the magnetic path direction of the pillar portion. In a reactor, since it is usual to provide a predetermined gap in a pillar part, it is preferable to arrange a pillar part by arranging a plurality of partial cores via a nonmagnetic spacer.
In a preferred embodiment, the magnetic component is a reactor in which a nonmagnetic spacer is interposed in the magnetic path of the core. In the case of the reactor, as described above, a non-magnetic spacer for preventing magnetic saturation is interposed between the core pillars (or between the pillars and the magnetic coupling part). In this case, when the column portion is reduced in the magnetic path direction by energizing the coil, the non-magnetic spacer and the end face of the core bonded to the non-magnetic spacer are peeled off, and as a result, the amount of magnetic flux changes thereafter. As a result, the end face of the core and the nonmagnetic spacer repeatedly collide with each other to generate a loud noise or mechanically damage the nonmagnetic spacer.
On the other hand, in the present invention, one end of the core in the column magnetic path direction, that is, one of the two magnetic coupling portions is a free end against vibration in the column magnetic path direction. One of the two magnetic coupling portions can easily follow this movement when being reduced and displaced, and as a result, the nonmagnetic spacer can be well prevented from peeling off from the core end face, and vibration and noise can be prevented. Can be reduced.
In a preferred aspect, the other of the two magnetic coupling portions is fastened to the case. If it does in this way, fixation to the case of the magnetic connection part of a core will become easy.
In a preferred aspect, the guide portion includes a projecting wall portion projecting from the side wall of the case facing one of the two magnetic coupling portions toward the other of the two magnetic coupling portions. In this way, the protruding wall portion can be easily manufactured by an aluminum die casting method or the like, and displacement of the free end side magnetic coupling portion in a direction different from the column magnetic path direction can be well prevented. Preferably, the projecting wall portion is formed in a square shape in which the magnetic coupling portion is accommodated. If it does in this way, the displacement to all the directions at right angles to the column part magnetic path direction of the magnetic connection part by the side of a free end can be controlled.
In a preferred aspect, the guide portion is made of a sealing resin body filled in the case. Suitably, a guide part consists of the cavity of the sealing resin body which accept | permits the displacement to the pillar part magnetic path direction of a core. In this way, with a simple process and structure, it is possible to regulate the other direction while securing the displacement of the free end type magnetic coupling portion and the column portion in the column magnetic path direction, and sealing. The cavity of the stop resin body can well surround a space generated by displacement, that is, expansion and contraction of the magnetic coupling portion and the column portion in the column portion magnetic path direction to prevent foreign matter from entering, and air remaining in the cavity. Can perform the function of preventing the expansion and contraction because it compresses and expands along with expansion and contraction in the magnetic path direction of the magnetic coupling portion and the column portion. Note that the adhesiveness between the free end side portion of the core and the sealing resin body inhibits the displacement of the self-end side portion in the direction of the column magnetic path, and also has a mechanical adverse effect on the sealing resin body. Therefore, it is preferable to perform resin sealing in a state where at least a portion on the free end side of the core is previously covered with a resin sheet or a resin cylinder portion.
In a preferred aspect, the guide portion includes an elastic member that is supported by the case and elastically supports one of the two magnetic coupling portions so as to be displaceable in the magnetic path direction of the column portion. In this way, the elastic member can support or hold the free end portion of the core, that is, one of the two magnetic coupling portions so as to be displaceable in the direction of the column magnetic path. This is advantageous because one of the connecting portions is given an elastic force for returning to the original position.
DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of a reactor adopting the invention will be described with reference to the drawings. This reactor is used for current smoothing of a DCDC inverter for vehicles. However, the present invention should not be construed as being limited to the following embodiments, and it goes without saying that the technical idea of the present invention may be realized using other known techniques.
The whole structure of this reactor is shown in FIG.1 and FIG.2. The reactor 1 has a soft magnetic square core 2 and a coil 3 wound around the square core 2.
The U-shaped core 2 is formed by abutting two U-shaped cores 4 having the same shape. The U-shaped core 4 will be described with reference to FIGS. The U-shaped core 4 has two rectangular column portions 5 and one magnetic coupling portion 6 each formed by molding soft magnetic powder, and is formed in a U shape as a whole. Of course, a laminated steel sheet core may be used instead of the soft magnetic powder molded core.
The square column part 5 has two end faces (hereinafter also referred to as magnetic path end faces) through which magnetic flux enters and exits, and these two magnetic path end faces are arranged in parallel so as to face away from each other. The magnetic coupling portion 6 is a member that magnetically couples two rectangular column portions 5 that are arranged in parallel to each other, and has a small number of column portions that are continuous with the rectangular column portion 5. Bolt fastening holes 7 are formed in each corner of the magnetic coupling part 6 in the direction perpendicular to the magnetic path. The magnetic coupling part 6 has two magnetic path end faces on the same plane, and a magnetic path gap is formed between one magnetic path end face of the magnetic coupling part 6 and one magnetic path end face of one rectangular column part 5. A non-magnetic and electrically insulating spacer 8 is formed for forming the. In the U-shaped core 4 shown in FIGS. 3 and 4, the end surfaces of the magnetic paths on the spacer 8 side of the two rectangular pillar portions 5 are exposed. The exposed magnetic path end faces of the two rectangular column parts 5 are also referred to as exposed magnetic path end faces 9. The B-shaped core 2 is configured by individually butting two exposed magnetic path end faces 9 of the two U-shaped cores 4 respectively. Note that a spacer similar to the spacer 8 is interposed between the two exposed magnetic path end faces 9 that are abutted with each other, as will be described later. The two rectangular column parts 5 which are abutted with each other are substantially accommodated in the coil 3 to form the column part referred to in the present invention. Therefore, the square-shaped core 2 is composed of two pillar portions and two magnetic coupling portions 6. Hereinafter, the two pillar portions may be referred to as a first pillar portion and a second pillar portion.
The coil 3 is shown in FIG. The coil 3 is formed by connecting a first coil portion 10 wound around the first pillar portion of the lower core 2 and a second coil portion 11 wound around the second pillar portion of the lower core 2 in series. Become. Since the total four rectangular column parts 5 constituting the first column part and the second column part each have a prismatic shape, the first coil part 10 and the second coil part 11 each have a rectangular cylindrical coil shape. The first coil portion 10 and the second coil portion 11 are configured by bending a thick plate-like rectangular wire whose surface is coated with an insulating film in the width direction. The coil 3 is formed by winding a single flat wire, and the thickness direction of the flat wire is parallel to the magnetic path direction of the rectangular column portion 5.
The coil 3 will be described in more detail with reference to FIG.
Reference numerals 12 to 15 denote end portions (also referred to as terminal portions) of the first coil portion 10 and the second coil portion 11, and the insulating film at the tip portions is peeled off by a predetermined dimension. The first end portion 12 of the first coil portion 10 protrudes forward from the lower left side of the first coil portion 10, and the end portion 13 of the first coil portion 10 protrudes forward from the upper right side of the first coil portion 10. The end portion 14 of the second coil portion 11 protrudes forward from the upper left side of the second coil portion 11, and the start end portion 15 of the second coil portion 11 protrudes forward from the upper left side of the second coil portion 11. Further, the terminal end portion 13 of the first coil portion 10 and the start end portion 15 of the second coil portion 11 are overlapped and welded in the vertical direction in FIG. 5, that is, in the magnetic path direction (column portion magnetic path direction) of the rectangular column portion 5. ing.
(Half core)
The U-shaped core 4 and the spacer 8 described above are integrated by resin insert molding to constitute a U-shaped half core 16 shown in FIG. That is, the U-shaped half core 16 includes the U-shaped core 4 and the spacer 8 and the resin coating portion 17 that covers them. As shown in FIG. 6, the resin coating portion 17 has irregularities for engaging and fitting the two U-shaped half cores 16. In this embodiment, the exposed magnetic path end surfaces 9 of the two rectangular column parts 5 are exposed from the resin coating part 17, but may be covered by the resin coating part 17 to a substantially constant thickness. In this case, the portion of the resin coating portion 17 that covers the exposed magnetic path end face 9 constitutes a spacer.
The resin coating portion 17 is located at the center in the left-right direction of the two rectangular column portions 5 (actually covered by the resin coating portion 17) arranged in parallel with each other, and extends in the front-rear direction. The support 18 is integrally provided. The sensor holding spacer 18 may be manufactured separately from the resin coating portion 17. The sensor holding spacer 18 is a resin plate and is nonmagnetic and electrically insulating. Eventually, the square core 2 of the reactor 1 has a total of six magnetic gaps. The sensor holding spacer 18 is chamfered at the front and upper corners to constitute a linear taper surface 19 for defining a groove for inserting a temperature sensor described later.
(Assembly of reactor 1)
The assembly of the two U-shaped half cores 16 and the coil 3 will be described with reference to FIG. A spacer 20 is disposed between the exposed magnetic path end faces 9 of the two U-shaped half cores 16. The spacer 20 is, for example, a plate material such as resin, glass, or ceramic, and is fixed to the core end surface with an adhesive. Reactor 1 formed in this way is housed in a metal case 21 made of an aluminum alloy having a front end opening as shown in FIG. 8. Mold resin 22 is sealed in metal case 21 to seal reactor 1. ing.
As shown in FIG. 8, the metal case 21 has a stepped protrusion 23 a protruding rearward at the center in the vertical direction of the bottom surface 23 on the rear end side. The metal case 21 has case holes 24 (see FIG. 9) respectively communicating with the two bolt fastening holes 7 provided in either of the two U-shaped cores 4. In FIG. 24 is not visible.
(Vehicle DCDC converter)
Next, the operation of assembling the reactor 1 to the vehicle DCDC converter will be described below with reference to FIG. FIG. 9 is a diagram illustrating a main part of the DC-DC converter for a vehicle.
25 is a liquid-cooled inverter device for a DC-DC converter for a vehicle, and this inverter device 25 has a semiconductor card module 26 in which main electrodes are exposed on a total of 12 surfaces each incorporating a semiconductor element. The card module 26 is alternately stacked with a total of 13 liquid cooling fins 27. In addition, an electrical insulating film or sheet is interposed between the semiconductor card module 26 and the liquid cooling fin 27 for electrical insulation during the lamination. Note that a total of 12 semiconductor card modules 26 constitute switching elements or flywheel diodes for each of the three-phase arms. The liquid cooling fins 27 are formed by overlapping two identical aluminum plates and brazing their outer peripheral edges, and a liquid flow path is formed in the vertical direction inside. In addition, among the liquid cooling fins 27, black thick lines extending vertically in FIG. 9 indicate outer peripheral edges of the brazed liquid cooling fins 27. The upper ends of the liquid cooling fins 27 are brazed so that the liquid flow paths are formed in the left-right direction, thereby forming a so-called inflow header. Similarly, the lower end portions of the liquid cooling fins 27 are brazed so that the liquid flow paths are formed in the left-right direction, thereby forming a so-called outflow header. In FIG. 9, a cooling liquid inflow pipe 29 and a cooling liquid outflow pipe 30 are brazed to the rightmost liquid cooling fin 27. Of course, the coolant inflow pipe 29 communicates with the right end of the inflow header, and the coolant outflow pipe 30 communicates with the right end of the outflow header.
Reference numeral 31 denotes an aluminum alloy converter housing (case referred to in the present invention) that houses a DCDC converter for a vehicle, and is die-cast in a square box shape with one end opening. The above-described liquid cooling type inverter device 25 is fixed to the converter casing 31 together with the liquid cooling device having the SPS structure described above.
Adjacent to the right end of the liquid-cooled inverter device 25, the reactor 1 is fixed by a bolt (not shown) that passes through the bolt fastening hole 7 and the case hole 24 and is fastened to the converter housing 31. . Only the bolt fastening hole 7 of the magnetic connecting portion 6 on the upper end side of the reactor 1 is fastened, but the bolt fastening hole 7 of the magnetic connecting portion 6 on the lower end side of the reactor 1 is free. That is, the metal case 21 that accommodates the reactor 1 does not have the case hole 24 that communicates with the bolt fastening hole 7 of the magnetic coupling portion 6 on the lower end side of the reactor 1, and as a result, the reactor 1 is connected to the converter housing 31. One end is supported in the column magnetic path direction (vertical direction in FIG. 9), and the magnetic coupling portion 6 on the lower end side of the reactor 1 is a free end with respect to the metal case 21 and the converter housing 31.
A side wall 21 a on the left end side of the metal case 21 that houses the reactor 1 is disposed in close contact with the right main surface of the rightmost liquid cooling fin 27 that forms the right end surface of the liquid cooling inverter device 25. In addition, in order to improve the adhesiveness between the left end side wall 21a of the metal case 21 and the rightmost liquid cooling fin 27, heat conductive grease may be applied, or both may be joined by various methods. .
Of the first coil portion 10 and the second coil portion 11 in the metal case 21, the outer peripheral surface of the first coil portion 10 is the rightmost side via the mold resin in the metal case 21 and the side wall 21 a of the metal case 21. The liquid cooling fins 27 are cooled. That is, among the liquid cooling fins 27 of the liquid cooling type inverter device 25, the outer main surface of the outermost liquid cooling fin 27 is not used for cooling the semiconductor module. The outer main surface of the cold fin 27 is used for heat transfer cooling of the reactor 1.
In this embodiment, the outermost liquid cooling fin 27 faces the outer peripheral surface of the first coil portion 10 through the side wall of the metal case 21 and the mold resin. Thereby, the coil 3 that needs to be cooled in preference to the core is cooled well. The second coil part 11 is cooled well through the excellent thermal conductivity of the rectangular wire constituting the first coil part 10. Note that the arrangement of the reactor 1 may be changed so that both the outer peripheral surface of the first coil unit 10 and the outer peripheral surface of the second coil unit 11 are opposed to the outermost liquid cooling fin 27.
Further, since the cooling liquid inflow pipe 29 and the cooling liquid outflow pipe 30 are interposed, the metal case 21 is accommodated in the metal case 21 by bringing the cooling liquid inflow pipe 29 and the cooling liquid outflow pipe 30 into contact with each other. The reactor 1 thus made can be cooled well from three sides.
In the above embodiment, the metal case 21 and the converter housing 31 are configured separately and fastened. However, as shown in FIG. 10, the metal case 21 that accommodates the reactor 1 and the converter housing 31 are integrally formed with a die. It may be cast to form an integral case. In this case, the side wall 21 a, which is one of the four rectangular side walls corresponding to the metal case 21 of the integral case, comes into contact with the outermost liquid cooling fin 27.
The four side walls of the metal case 21 include a side wall 21 a that faces the outer peripheral surface of the first coil unit 10, a side wall that faces the outer peripheral surface of the second coil unit 11, and two side walls that face the magnetic coupling unit 6. . Here, when the side wall 21a of the metal case 21 facing the first coil portion 10 (or the outer peripheral surface of the second coil portion 11) is in close contact with the outermost liquid cooling fin 27 (when the coil is brought close to the cooler) a When the side wall of the metal case 21 facing the magnetic coupling portion 6 of the square core 2 is in close contact with the outermost liquid cooling fin 27 (when the core is brought close to the cooler) b, The center temperature of the reactor 1 was measured. The measurement results are shown in FIG. In FIG. 11, with the passage of time in a state where a constant current was passed through the coil, in the case of a, the temperature slightly exceeded 100 ° C., but in the case of b, the value was close to 120 ° C. .
Next, the arrangement of the temperature sensor 32 used for the temperature detection will be described with reference to FIGS. The temperature sensor 32 has a built-in thermistor and is disposed at a central position X (see FIG. 2) in the column magnetic path direction of the coil 3 in an intermediate gap between the first coil unit 10 and the second coil unit 11. Yes. Moreover, it arrange | positions in the front-back direction center part (refer FIG. 8) which is the axial direction of the 1st coil part 10 and the 2nd coil part 11. As shown in FIG. That is, the temperature sensor 32 is arranged at the three-dimensional center position X of the reactor 1. This position is a portion where the temperature is highest in the reactor 1 due to heat generated by the first coil unit 10 and the second coil unit 11 on both sides, and the temperature sensor 32 detects the maximum temperature of the reactor 1. The measurement result of each part temperature of the reactor 1 is shown in FIG. It can be seen that the temperature at the central position X of the reactor 1 is considerably higher than the coil temperature (peripheral part) and the core temperature (peripheral part).
The arrangement of the temperature sensor 32 will be described in more detail with reference to FIG.
The sensor holding spacer 18 integrally formed with the resin coating portions 17 of the two U-shaped cores 4 faces the vertical direction and forms a groove portion 18A in which the temperature sensor 32 is accommodated. The groove 18A has an opening that is partitioned by the linear tapered surfaces 19 of the two sensor holding spacers 18 and gradually increases toward the front. The straight bar-shaped temperature sensor 32 is inserted from the opening of the groove 18A to the center position (see FIG. 2) X. After the temperature sensor 32 is inserted, a liquid or jelly-like mold resin is injected into the metal case 21 and solidified, whereby the reactor 1 and the temperature sensor 32 are fixed at predetermined positions. The sensor holding spacer 18 holds the temperature sensor 32 when the mold resin is injected to prevent displacement. In the case where the two sensor holding spacers 18 are formed separately from the resin coating portion 17, the two sensor holding spacers 18 can be replaced by one grooved resin plate.
(Reactor 1 fixing structure)
As described above, in this embodiment, the reactor 1 is fixed by a bolt (not shown) that passes through the bolt fastening hole 7 and is fastened to the converter housing 31. However, in this embodiment, only the bolt fastening hole 7 of the magnetic coupling part 6 on the upper end side of the reactor 1 is fastened, but the bolt fastening hole 7 of the magnetic coupling part 6 on the lower end side of the reactor 1 is free. . As a result, the reactor 1 is supported at one end in the column magnetic path direction (vertical direction in FIG. 9) by the converter housing 31 integrated with the metal case 21, and the magnetic coupling portion 6 on the lower end side of the reactor 1 It is a free end with respect to the converter housing 31.
As described above, since one of the two magnetic coupling portions 6 is a free end, the bonded portion between the rectangular column portion 5 and the spacers 8 and 20 does not peel off, and the generation of a large noise generated from this portion after peeling is excellent. Can be prevented. Moreover, the difference in the coefficient of thermal expansion between the metal case 21 and the reactor 1 can be absorbed well.
The mold resin 22 adheres to the surface of the magnetic coupling portion 6 and the like, and inhibits displacement of one of the two magnetic coupling portions 6 (the free end of the core in the column magnetic path direction) in the column magnetic path direction. To do. In order to alleviate this problem, a lubricant is applied to the core surface or the like before the resin molding step, or at least the surface of the magnetic coupling portion 6 on the free end side is subjected to sliding displacement in the direction of the column magnetic path. It is possible to adopt a technique such as resin molding after covering a possible resin sheet or resin cylinder. Furthermore, according to this embodiment, the vibration force in the columnar magnetic path direction transmitted to the metal case 21 from the square-shaped core 2, particularly the magnetic coupling portion 6 is reduced, so that the vibration of the metal case 21 can be reduced. .
Another embodiment will be described with reference to FIGS. FIG. 13 is a schematic partial front view of the reactor device, and FIG. 14 is a schematic partial cross-sectional view of the reactor device.
The bottom plate 21e of the rectangular box-shaped metal case 21 has a stepped surface 21f on which the magnetic coupling portion 6 is placed. Both ends of the magnetic coupling portion 6 are fixed by a U-shaped band plate 21h fastened to the stepped surface 21f by screws 21g. Although 22 is a mold resin, it can be omitted.
Another embodiment will be described with reference to FIGS. 15 and 16. FIG. 15 is a schematic partial front view of the reactor device, and FIG. 16 is a schematic partial cross-sectional view of the reactor device.
In this embodiment, after the bolt fastening hole 7, which is a through-hole penetrating one of the two magnetic coupling portions, is penetrated by the bolt 21 i as in the first embodiment, the step of the metal case 21 is made. It is fastened to a case hole (not shown) provided on the surface 21f. The weight of the reactor 1 is carried on the step surface 21f. In this embodiment, the same effects as those of the first and second embodiments can be obtained.
Another example of the support structure of the magnetic coupling portion 6 that forms the free end will be described with reference to FIGS. 17 and 18. In the first embodiment, the mold resin 22 itself is used as a support structure for the magnetic coupling portion 6 that forms a free end, and a lubricant is applied to the surface of the magnetic coupling portion 6 in advance. Displacement in the direction was possible.
In this embodiment, a U-shaped wall portion 21j is projected from the side wall 21d of the metal case 21 so as to cover the stepped surface 21f of the metal case 21, and a square hole 21k is formed by the wall portion 21j and the stepped surface 21f. . The distal end portion of the magnetic coupling portion 6 on the free end side is accommodated in the rectangular hole 21k, and a gap is secured between the magnetic coupling portion 6 and the side wall 21d. In this way, it is possible to prevent undesired displacement in other directions while allowing displacement of the magnetic coupling portion 6 on the free end side in the column magnetic path direction. In addition, you may comprise this square hole 21k by each resin cylinder fixed to the inner surface in the metal case 21. FIG.
Another example of the support structure of the magnetic coupling portion 6 forming the free end will be described with reference to FIGS. 19 and 20. This embodiment is characterized in that the square hole 21k of the fourth embodiment is configured by a square tube 21m made of an elastic body such as rubber. The square tube 21m made of this elastic body is fixed on the stepped surface 21f of the metal case 21 and bonded to the side wall 21d of the metal case 21.
In this way, it is possible to ensure the displacement of the magnetic coupling portion 6 on the free end side in the column magnetic path direction while utilizing the damping force and vibration energy dissipation of the elastic body.
In the first to third embodiments described above, the reactor 1 is enclosed and sealed with the mold resin 22. However, the mold resin 22 may be omitted by making the metal case 21 have a sealed structure.
It is a perspective view of the reactor of Embodiment 1. It is a front view of the reactor of Embodiment 1. It is a front view which shows a U-shaped core. It is a disassembled perspective view of a U-shaped core. It is a perspective view of a coil. It is a perspective view of a U-shaped half core. It is a disassembled perspective view of the reactor of Embodiment 1. FIG. It is an AA arrow directional cross-sectional view of the reactor of Embodiment 1. It is a partial front view of the DCDC converter for vehicles by which the reactor was mounted. It is a disassembled perspective view of the DCDC converter for vehicles by which the reactor was mounted. It is a characteristic view which shows the difference in coil temperature at the time of making the core side surface and coil side surface of a reactor close to a liquid cooling fin. It is a characteristic view which shows the difference in the temperature of each part of a reactor. It is a model front view of the reactor apparatus in 2nd Embodiment. It is a schematic cross section of the reactor apparatus in 2nd Embodiment. It is a typical fragmentary sectional view of the reactor apparatus in 3rd Embodiment. It is a model partial front view of the reactor apparatus in 3rd Embodiment. It is a model fragmentary sectional view of the reactor apparatus in 4th Embodiment. It is a model partial front view of the reactor apparatus in 4th Embodiment. It is a typical fragmentary sectional view of the reactor apparatus in 5th Embodiment. It is a model partial front view of the reactor apparatus in 5th Embodiment.
DESCRIPTION OF SYMBOLS 1 Reactor 2 B-shaped core 3 Coil 4 U-shaped core 5 Square column part 6 Magnetic coupling part 7 Bolt fastening hole 8 Spacer 9 Exposed magnetic path end surface 10 Coil part 10a Left side 10b Front side 10c Right side 11 Coil part 11b Front side 11c Left side 12 Start end portion 12a End portion 13 End portion 13a End portion 14 End portion 14a End portion 15 Start end portion 16 U-shaped half core 17 Resin coating portion 18 Sensor holding spacer 18A Groove portion 19 Linear taper surface 20 Spacer 21 Metal case 21a Side wall 22 Mold resin 23 Bottom surface 23a Step protrusion 24 Case hole 25 Liquid cooling type inverter device 26 Semiconductor card module 27 Liquid cooling fin 29 Cooling liquid inflow pipe 30 Cooling liquid outflow pipe 31 Converter housing 32 Temperature sensor 21e Metal case bottom plate 21f Metal case step surface 21g Screw 21h U-shaped strip 21i Bolt 21j U-shaped wall 21k Square hole 21m Square tube
At least two pillar parts parallel to each other, one end side magnetic coupling part magnetically connecting one end part of the pillar part, and the other end side magnetic coupling magnetically connecting the other end parts of the pillar part A soft magnetic core comprising a closed magnetic circuit
A coil wound around the column;
A square box-like case that has a bottom plate portion to which the core is fastened and accommodates the core and the coil;
In the magnetic part that the column part expands and contracts in the magnetic path direction of the column part by alternating current energization to the coil,
A guide portion fixed to the case and holding one of the two magnetic coupling portions so as to be displaceable in the magnetic path direction of the column portion;
The other of the two magnetic coupling portions is fixed to a bottom plate portion of the case.
The magnetic component according to claim 1,
A magnetic component which is a reactor in which a nonmagnetic spacer is interposed in the magnetic path of the core.
The magnetic component according to claim 2,
The other of the two magnetic coupling portions is a magnetic component fastened to the case.
The guide part is a magnetic component including a projecting wall part projecting from the side wall of the case facing one of the two magnetic coupling parts toward the other of the two magnetic coupling parts.
The guide part is a magnetic component made of a sealing resin body filled in the case.
The guide part is a magnetic component having an elastic member that is supported by the case and elastically supports one of the two magnetic coupling parts so as to be displaceable in the magnetic path direction of the column part.
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JP2005374543A JP2007180140A (en) 2005-12-27 2005-12-27 Magnetic component
JP2007180140A true JP2007180140A (en) 2007-07-12
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