JP5398636B2 - Magnetic element - Google Patents

Description

  The present invention relates to a magnetic element in which a magnetic member and a winding are integrally formed, and in particular, a reactor used in a booster circuit of an inverter that is a power conversion device for a vehicle driving power motor such as an electric vehicle or a hybrid vehicle. The present invention relates to a magnetic element.

  Conventionally, in this type of magnetic element, since an alternating current flows due to the operation of the booster circuit, various kinds of vibration and noise due to the Lorentz force generated between the windings and the electromagnetic force, magnetostriction, etc. generated in the magnetic member are reduced. Efforts are being made. In addition, in the conventional magnetic element, since the winding that becomes a heat source during operation and the magnetic member are integrated, the heat dissipation is excellent, but cracks due to thermal stress may occur. Efforts are being made to reduce and further improve heat dissipation.

  For example, a method of reducing vibration by setting the elastic modulus of the magnetic member itself to 3000 MPa or more is disclosed (Patent Document 1).

  In addition, as a method for reducing the transmission of vibration, it is also known to provide a low elastic layer between a case housing a magnetic element (Patent Document 2).

  Furthermore, as a method for suppressing the occurrence of cracks due to thermal stress, a technique of incorporating low-elasticity powder is known (Japanese Patent Application No. 2008-291746).

JP 2006-4958 A JP 2007-27185 A

  The Lorentz force between the windings, which is the driving source for vibration of the magnetic element as in Patent Document 1, and the electromagnetic force and magnetostriction generated in the magnetic member depend on the current density, the magnetic flux density, etc. Has a three-dimensional distribution that circulates in the magnetic member, and therefore has a plurality of patterns in its direction and size. Further, the structure of the magnetic element is mainly composed of a winding, an insulator, and a magnetic body, and the natural vibration mode as a magnetic element formed by combining these elements has a plurality of patterns. Here, when the pattern of the vibration driving force generated by the circuit operation and the pattern of the natural vibration due to the structure of the magnetic element are the same, and the frequency of the driving force and the frequency of the natural vibration are close to each other, the vibration generated particularly as the magnetic element Is undesirably large.

  However, in order to reduce the vibration generated in the magnetic element, it is often difficult to reduce the vibration driving force itself of the magnetic element because it changes the magnetic circuit and the magnetic material itself. In addition, since the natural vibration as a structure is determined by mass and elasticity, the natural frequency of each mode can be changed in a uniform direction by changing the elastic modulus of the magnetic member. The patterns could not be changed separately, and it was difficult to optimize as a whole, and it was difficult to reduce the occurrence of vibration.

  Moreover, in the technique of patent document 2, when incorporating a metal member, such as aluminum, in order to fix a reactor to a case, or in order to improve heat dissipation, a vibration will be transmitted through the member, and a vibration transmission is reduced. As a result, it has been necessary to reduce the vibration level of the vibration source itself.

  Further, in the method proposed by the present inventors, the thermal stress is generated with respect to the winding and the diameter of the magnetic body, so that the absolute amount of deformation is large, and the range of the deformation also relates to the entire circumferential direction. It was not possible to improve the source of the generation of thermal stress.

  Therefore, an object of the present invention is to solve the above-described problems, and to provide a magnetic element that has a small amount of vibration generated by an energizing operation, is less likely to cause cracking due to thermal stress, and has good heat dissipation.

  In order to solve the above problems, the present invention provides a magnetic element in which a magnetic member and a winding are integrally formed, and the magnetic member is divided into two or more parts by a non-magnetic material in a direction that does not disturb magnetic flux. Magnetic element. The nonmagnetic material is a magnetic element integrated with the storage case. Further, the magnetic element is different in mechanical properties (elastic modulus, density) and the like for each of the divided parts. Further, the nonmagnetic material is a magnetic element having a different elastic modulus from that of the magnetic member.

That is, according to the present invention, in the magnetic element in which the magnetic member and the winding are integrally formed, the magnetic member is at least 2 divided by a partition made of a non-magnetic material in a direction parallel to the central axis of the winding. The partition is formed of a plurality of rectangular partition pieces, and is integrally formed so that one side of the partition piece coincides with the central axis, and the winding is wound around the partition piece. A magnetic element characterized in that a notch for housing is provided is obtained.

  In addition, according to the present invention, the magnetic element is obtained in which the partition has an elastic modulus different from that of the magnetic member.

  According to the invention, it is possible to obtain the magnetic element described above, wherein the partition is formed integrally with a case for housing the magnetic member and the winding.

  As described above, according to the present invention, in the magnetic element in which the magnetic member and the winding are integrally formed, the mass of the magnetic body in each divided portion is small, and the elasticity of the magnetic member and the partition is different, so that resonance occurs. Thus, it is possible to easily obtain a magnetic element in which vibration due to operation is less likely to occur. Moreover, since the volume of each division part of a magnetic body is small and the adhesion area with the partition integral with a case is large, the magnetic element excellent in heat stress and heat dissipation can be obtained.

It is explanatory drawing of the magnetic element in embodiment of this invention. FIG. 1A is a cross-sectional view. FIG. 1B is a longitudinal sectional view. FIG. 1C is a perspective view. It is a top view of the magnetic element of the other example in embodiment of this invention. FIG. 2A is a diagram showing a case of five divisions. FIG. 2B is a diagram showing a case of 6 divisions. FIG. 2C is a diagram showing a case of 8 divisions. It is a top view of the magnetic element of the other example in embodiment of this invention. It is explanatory drawing of the conventional magnetic element. FIG. 4A is a cross-sectional view. FIG. 4B is a longitudinal sectional view.

Hereinafter, embodiments of the present invention will be described in detail.
FIG. 1 is an explanatory view of a magnetic element according to an embodiment of the present invention, in which FIG. 1 (a) is a transverse sectional view, FIG. 1 (b) is a longitudinal sectional view, and FIG. 1 (c) is a perspective view. In FIG. 1A, the magnetic element is cut at the center in the height direction. In FIG.1 (b), the center part of the partition is cut and shown. In FIG. 1C, the winding is omitted.

  As shown in FIG. 1, a magnetic element 1 according to an embodiment of the present invention is composed of a winding 2, a magnetic member 1 a for casting it, and a case 3 for housing them. After setting the winding 2 in the case 3, the magnetic element 1 is obtained by pouring a predetermined amount of slurry of the magnetic member, and then heating and curing. Here, as shown in FIGS. 1 (a) and 1 (c), a direction in which the magnetic flux of the magnetic member 1a is not obstructed in advance on the inner wall of the case 3 (the same direction as the central axis of the winding 2, that is, a parallel direction) The magnetic element 1 in which the magnetic member 1a is divided can be obtained by providing the partition 4 and storing the winding 2 in the partition 4 and pouring the magnetic member 1a.

  The case 3 in the present invention has, for example, a rectangular tube shape. A partition 4 is provided inside the case 3. The partition 4 is composed of four partition pieces 4a having a rectangular outer shape, and is integrally formed. The four partition pieces 4a have an equal angle of 90 ° between adjacent partition pieces 4a. Further, the partition piece 4a is provided with a notch 4b having a length sufficient for inserting a winding. The shape of the notch 4b is the same rectangle as the cross section of the winding 2 cut in a direction perpendicular to the central axis. The case 3 and the partition 4 are preferably integrated, but may be separate. In the case of separate bodies, the case 3 and the partition 4 may not be the same material. If the thickness of the partition 4 is too thick, the magnetic path area is reduced, and if it is too thin, the heat transfer is deteriorated and the strength as a partition wall is also reduced, so that the diameter of the magnetic element 1 is about 1/100 to 5/100. desirable.

  Further, the number of partition pieces of the partition of the case 3 can be determined as appropriate depending on the number of divisions and the interval. For example, it can be set as shown in FIGS. 2A and 2B are plan views of another example of the magnetic element according to the embodiment of the present invention, in which FIG. 2A shows a case of 5 divisions, and FIG. 2B shows a case of 6 divisions. FIG. 2C is a diagram showing a case of 8 divisions. FIG. 3 is a plan view of another example of the magnetic element according to the embodiment of the present invention. 2 and 3, the magnetic member and the winding are omitted. As shown in FIG. 2A, when a partition 14 consisting of five partition pieces is used and equally divided into five, the magnetic element 11 having a configuration in which the angle between adjacent partition pieces is 72 ° is obtained. . In addition, as shown in FIG. 2B, when a partition 24 composed of six partition pieces is used and equally divided into six, the angle between adjacent partition pieces is 60.degree. can get. In addition, as shown in FIG. 2C, when a partition 34 composed of eight partition pieces is used and equally divided into eight, the angle between adjacent partition pieces is 45.degree. can get. Further, the angles formed by adjacent partition pieces can be non-uniform. As shown in FIG. 3, the corresponding four-divided portion may have a 15 ° or 30 ° structure. The number of divisions in the case of unevenness is not limited to this. In practice, 2 to 8 divisions are preferable. In particular, four divisions are optimal.

  In addition, the material of case 3 has sufficient heat resistance against heat generation due to energizing conditions used as a magnetic element and temperature rise due to operating environment, cooling mechanism, etc., such as elastic modulus, breaking strength and breaking elongation. As long as it is cold resistant and does not break due to thermal stress, it can be any material that does not break easily due to handling such as assembly and fitting with a winding. Aluminum can be used. Further, any material may be used as long as the thermal conductivity is sufficiently high and the linear expansion coefficient is allowed, and pure iron, stainless steel, plastic having high thermal conductivity, or the like can be used.

As the magnetic member 1a in the present invention, for example, a composite magnetic material that is made into a slurry by mixing iron-based magnetic powder such as Fe-Si-based or Fe-Si-Al-based and liquid resin such as thermosetting is used. it can. Iron-based magnetic powders contain a non-ferrous component and have a composition that reduces saturation magnetostriction and magnetocrystalline anisotropy, and iron loss can be reduced. Therefore, the non-ferrous component species and content are appropriately selected depending on the application. The thermosetting resin is preferably a low-viscosity resin so as to have sufficient fluidity when made into a slurry. In addition, the mechanical properties of the thermosetting resin after curing, such as elastic modulus, fracture strength, and elongation at break, are sufficient for heat generation due to energizing conditions used as magnetic elements and temperature rise due to usage environment, cooling mechanism, etc. It is necessary to have heat resistance and cold resistance and not to be damaged by thermal stress. For example, an epoxy resin having a high breaking strength or a silicone resin having a high elongation at break can be used .

  As the winding in the present invention, a rectangular wire wound in an edgewise shape has a high space factor and is suitable for downsizing, but a winding of a round wire may also be used. In addition, the winding shape of the winding is generally circular, but is not limited thereto, and may be an oval shape or a rectangle having corners R.

  The elastic modulus of the composite magnetic member is about 1 to 30 GPa, whereas for example, aluminum used as a partition is as large as 70 GPa, so the combined elastic modulus of the element in which these are integrated is higher than that of the composite magnetic member alone. Get higher. As a result, it is difficult to deform with respect to the driving force of vibration, that is, it is difficult to vibrate. Further, for example, the adjacent parts divided into four parts are cast and cured with a composite magnetic member produced using an epoxy resin having an elastic modulus of 3000 MPa after curing and an epoxy resin having a pressure of 1 MPa. The elastic modulus of the element can be changed from place to place. The magnetic element has a high natural frequency when the elastic modulus of the constituent member is high, and the natural frequency is low when the elastic modulus is low. Therefore, the magnetic element having the above configuration has a different natural frequency depending on the location. Since it is dispersed and unclear, resonance hardly occurs.

Below, the magnetic element of the Example of this invention is demonstrated.
Example 1
A magnetic element 1 having the structure shown in FIG. 1 was produced. The wire is a 0.8 mm thick and 9 mm wide flat copper wire with an AIW coating. The inner diameter is 60 mm, and it is wound 32 turns in an edgewise shape so that the two ends are facing upward. The terminal 2 was bent and the winding 2 was produced. The dimensions of the winding 2 are an outer diameter of 78 mm, an inner diameter of 60 mm, and a height of 32 mm.

Next, a mixture of a predetermined amount of a two-component mixed thermosetting epoxy resin XNR4455 and a curing agent XN1213 manufactured by Nagase ChemteX Corporation as a liquid insulating resin is taken in a container, the winding 2 is immersed, and the degree of vacuum is 4.0 × 10. Vacuum impregnation was performed at ² Pa, and after raising this, it was cured at 120 ° C. for 3 hours.

  After setting the winding 2 having cured insulating resin on the partition piece 4a of the case 3, the magnetic member 1a was cast and heat-cured to obtain the magnetic element 1 of Example 1. The magnetic element 1 has a diameter of 93 mm and a height of 51 mm. The case 3 has a thickness of 5 mm, and the partition 4 has a thickness of 2 mm. The magnetic member 1a is composed of 60% by volume of Fe 6.5% Si gas atomized powder as magnetic powder, and the remainder is a two-component mixed thermosetting epoxy resin made by Japan Epoxy Resin Epicoat 827 and Cure W at a predetermined ratio. And made.

(Example 2)
Magnetic elements 11, 21, and 31 having a partition structure shown in FIG. Example 1 was the same as Example 1 except that the number of partition pieces and the number of magnetic members were different from Example 1.

(Example 3)
A magnetic element 41 having a partition structure shown in FIG. 3 was produced. Example 1 was the same as Example 1 except that the number of partition pieces and the number of magnetic members were different from Example 1.

(Comparative example)
As a comparative example, a magnetic element 51 including a magnetic member 1a, a winding 2, and a case 3 as shown in FIG.

  In order to give a rapid temperature change to each of the 20 magnetic elements according to Examples and Comparative Examples produced as described above, the magnetic elements were held in a thermostatic bath at 150 ° C. for 2 hours and then immersed in water at 20 ° C.

  As a result, cracks did not occur in Examples 1 to 3, but cracks occurred in two of the elements in the comparative example. In the examples of the present invention, no crack was generated in any of the examples, and a magnetic element having higher reliability than the comparative example could be obtained.

  In addition, although the example of the partition of 4 or more division was shown in the above Example, the same effect was acquired also in 2 division and 3 division.

  The present invention is not limited to the above-described embodiments and examples, and various modifications can be made without departing from the gist of the present invention.

1, 11, 21, 31, 41, 51 Magnetic element 1a Magnetic member 2 Winding 3 Case 4, 14, 24, 34, 44, 54 Partition 4a Partition piece 4b Notch

Claims (3)

In the magnetic element in which the magnetic member and the winding are integrally formed, the magnetic member is divided into at least two or more divisions by a partition made of a non-magnetic material in a direction parallel to the central axis of the winding . The partition is formed of a plurality of rectangular partition pieces, and is integrally formed so that one side of the partition piece coincides with the central axis, and the partition piece is provided with a notch for storing the winding. A magnetic element characterized by the above. The magnetic element according to claim 1, wherein the partition has an elastic modulus different from that of the magnetic member. Magnetic element according to claim 1 or 2, wherein the partition is characterized in that which is formed integrally with the casing for housing the magnetic member and the winding.

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