CN106169354A - Reactor device and electric/electronic device - Google Patents

Reactor device and electric/electronic device Download PDF

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Publication number
CN106169354A
CN106169354A CN201610200599.2A CN201610200599A CN106169354A CN 106169354 A CN106169354 A CN 106169354A CN 201610200599 A CN201610200599 A CN 201610200599A CN 106169354 A CN106169354 A CN 106169354A
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China
Prior art keywords
encapsulant
core body
reactor
reactor device
housing
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CN201610200599.2A
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CN106169354B (en
Inventor
高桥利男
片濑直孝
水岛隆夫
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Alps Alpine Co Ltd
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Alps Green Devices Co Ltd
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Publication of CN106169354A publication Critical patent/CN106169354A/en
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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
    • H01F27/02—Casings
    • H01F27/022—Encapsulation
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K5/00—Heat-transfer, heat-exchange or heat-storage materials, e.g. refrigerants; Materials for the production of heat or cold by chemical reactions other than by combustion
    • C09K5/08—Materials not undergoing a change of physical state when used
    • C09K5/14—Solid materials, e.g. powdery or granular
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15308—Amorphous metallic alloys, e.g. glassy metals based on Fe/Ni
    • 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
    • H01F27/08—Cooling; Ventilating
    • H01F27/22—Cooling by heat conduction through solid or powdered fillings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/25—Magnetic cores made from strips or ribbons
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/266—Fastening or mounting the core on casing or support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Dispersion Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Thermal Sciences (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Soft Magnetic Materials (AREA)
  • Insulating Of Coils (AREA)

Abstract

The present invention provides reactor device and possesses the electric/electronic device of this reactor device.This reactor device possesses: reactor main body, and it possesses under top view core body in the form of a ring and is wound in the coil of core body；House the housing of reactor main body；And it is filled in the encapsulant between reactor main body and housing, core body is made up of the press-powder core body of the powder compact possessed the material press molding comprising Magnaglo, core body has: has the part being inserted in coil and marks off two line parts of magnetic circuit of linearity, and two kinks of the magnetic circuit arranging and marking off bending it are connected with each end of line part, encapsulant possesses: the first encapsulant between kink and housing, and the second encapsulant between at least some of of line part and housing, the Young's modulus of the first encapsulant is lower than the Young's modulus of the second encapsulant.

Description

Reactor device and electric/electronic device
Technical field
The present invention relates to reactor device and possess the electric/electronic device of this reactor device.
Background technology
The reactor device used in the booster circuit of hybrid motor vehicle etc., generating, converting equipment possesses: by ring The reactor main body that the core body of shape and the coil being wound in core body are constituted；House the housing of reactor main body；And it is filled in electricity Encapsulant (referring for example to patent documentation 1, patent documentation 2) between anti-device main body and housing.
When reactor device is applied in alternating current in use, due to the Magnetostrictive Properties of core body, make core body root Deform periodically according to the change of alternating current, produce vibration, heat from reactor main body.Encapsulant is required to stand The environment (such as motor vehicles) live the vibration from this reactor main body, being placed by reactor device is applied to reactor device Vibration, thus reactor main body is fixed on housing.
Citation
Patent documentation 1: Japanese Unexamined Patent Publication 2012-142379 publication
Patent documentation 2: Japanese Unexamined Patent Publication 2014-224189 publication
As shown in patent documentation 2, the encapsulant filled between reactor main body and housing is formed in the following way: When reactor main body is contained in housing, to irrigating (note type) curable composition between reactor main body and housing Thing, makes curable constituent solidify, is consequently formed encapsulant.Go out from the viewpoint that reactor main body is firmly fixed at housing Sending out, preferably encapsulant uses hard material, specifically uses the material that Young's modulus is high.But, it is possible to form hard The curable constituent of encapsulant is answered because volume contraction during solidification can apply stronger compression to the core body of reactor main body Power.When core body is subject to stronger compression stress, the magnetic characteristic of reactor main body, especially iron loss are had undesirable effect.Should Trend is especially pronounced in the case of reactor main body possesses press-powder core body.
As avoiding one of method causing this impact, it is considered to use and be difficult to when solidification apply compression stress to core body Material as forming the curable constituent of encapsulant.But, in this case, as the encapsulant of solidfied material Become soft material (material that Young's modulus is low), because of the vibration from reactor main body or from shaking outside reactor device Danger that is dynamic and that make reactor main body come off from housing increases.
Summary of the invention
The present invention completes in view of the foregoing, its object is to, it is provided that a kind of reactor device and possess this reactance The electric/electronic device of device device, it is possible to realize following effect: reduce in use generation reactor main body and come off this from housing The probability of one problem, and suppress the decline of the magnetic characteristic of reactor device.
One mode of the present invention provided to solve above-mentioned technical problem is a kind of reactor device, and it possesses: electricity Anti-device main body, it possesses under top view core body in the form of a ring and is wound in the coil of described core body；Housing, it houses described electricity Anti-device main body；And encapsulant, it is filled between described reactor main body and described housing, described reactor device Being characterised by, described core body is made up of press-powder core body, and this press-powder core body possesses the material press molding comprising Magnaglo The powder compact become, described core body has: two line parts, and said two line part has the part being inserted in described coil, And mark off the magnetic circuit of linearity；And two kinks, said two kink is continuous with each end of described line part Arranging, and mark off the magnetic circuit of bending, described encapsulant possesses: first between described kink and described housing is close Closure material；And the second encapsulant between at least some of of described line part and described housing, described first close The Young's modulus of closure material is lower than the Young's modulus of described second encapsulant.
When the curable constituent for forming encapsulant carries out cure shrinkage, suffered by the core body of reactor main body Compression stress effect that the magnetic characteristic of reactor device is caused change according to the shape of core body.Shape at core body In the case of shape is complicated shape, compared with the situation being shaped as the better simply shape such as bar-shaped of core body, have to magnetic characteristic, The effect especially caused iron loss becomes big trend.
To this, in the present invention, shape in the form of a ring will be positioned under top view in the way of marking off the magnetic circuit of Guan Bi Encapsulant between core body and housing is divided into situation (second sealing material of the part (line part) marking off linearity magnetic circuit Material) and mark off the situation (the first encapsulant) of part (kink) of magnetic circuit of non-linear shape and bending, second seals Material is the material of relative harder (Young's modulus is high), and the first encapsulant is the material of the most soft (Young's modulus is low).By It is made up of hard material in the second encapsulant, therefore, it is possible to reactor main body is firmly fixed at housing.For forming the The curable constituent of two encapsulants applies bigger compression stress by cure shrinkage to core body, but due to close by second The fixing core of closure material is line part, and therefore, the magnetic characteristic of the reactor device caused because of this line part is difficult to occur Deterioration.Due to the most soft and cure shrinkage affect that the first few encapsulant is positioned in core body there is relatively complicated shape Between kink and housing, therefore, the magnetic characteristic of the reactor device caused because of the kink of core body is difficult to deteriorate.This is Because when applying identical power to line part with kink, the impact that core body is caused by the stress in kink is very big, by The deterioration of this magnetic characteristic is the biggest, therefore, according to this opinion, reduces the impact on the stress that kink applies.Therefore, upper In the reactor device involved in the present invention stated, because forming the electricity that the cure shrinkage of the curable constituent of encapsulant causes The deterioration of the magnetic characteristic of anti-device device is difficult to produce.
From the easness etc. of operability, the curable constituent being preferably used to form encapsulant comprises resin system material Material.It is therefore preferable that described first encapsulant and described second encapsulant comprise resin system material.
Described second encapsulant can also comprise filler.As it has been described above, the Young's modulus of the second encapsulant is than The Young's modulus of one encapsulant is high, as the scheme of this Young's modulus of raising, uses the filling being made up of inorganic based material etc. Agent is the easiest.
The Young's modulus of the most described second encapsulant is more than 5GPa.By described second encapsulant, more surely Surely reactor main body is fixed on housing.
The Young's modulus of the most described first encapsulant is below 50MPa.Reason curable constituent shape can be reduced Cure shrinkage when becoming the first encapsulant and the degree to the compression stress that kink applies.
Described Magnaglo can also comprise from by Fe-Si-B system alloy, Fe-P-C system alloy and Co-Fe-Si-B system The powder of one or more the noncrystalline magnetic material selected in the group that alloy is constituted.Due to noncrystalline magnetic material ratio Relatively hard, therefore, in the case of Magnaglo comprises the powder of noncrystalline magnetic material, holds when being applied with external force to core body Easily accumulation is deformation.Accumulate the deformation easily magnetic characteristic to the reactor device possessing this core body in core body and cause bad shadow Ring.But, as it has been described above, in reactor device involved in the present invention, being used between reactor main body and housing The cure shrinkage of the curable constituent forming encapsulant is difficult to make the magnetic characteristic of reactor device to deteriorate.Therefore, exist In reactor device involved in the present invention, even if comprise the situation of noncrystalline magnetic material at the Magnaglo contained by core body Under, magnetic characteristic is also difficult to deteriorate.
Described noncrystalline magnetic material can also be made up of Fe-P-C system alloy.The magnetostriction constant of above-mentioned material is sometimes Higher, even if but this situation, the magnetic characteristic of reactor device involved in the present invention is also difficult to deteriorate.
Above-mentioned powder compact can also be containing making described Magnaglo be bonded in the other materials contained by described powder compact Bonding component.In the case of there is bonding component, it is easier to make powder compact keep shape.It addition, bonding component sometimes Preferentially deform between Magnaglo, in this case, it is difficult in Magnaglo, accumulate deformation.Above-mentioned bonding component preferably wraps Containing the composition formed based on resin material.
As another way, the present invention provides the electric and electronic being provided with above-mentioned reactor device involved in the present invention Equipment.
Invention effect
According to the present invention, it is provided that be capable of the reactor device of following effect: reduce and in use produce reactor Main body comes off from housing the probability of this problem, and suppresses the decline of the magnetic characteristic of reactor device.It addition, also provide for tool The electric/electronic device of standby above-mentioned reactor device.
Accompanying drawing explanation
Fig. 1 is the axonometric chart of the shape schematically illustrating the reactor device involved by one embodiment of the present invention.
Fig. 2 is the shape schematically illustrating the core body that the reactor device involved by one embodiment of the present invention is possessed Top view.
Fig. 3 is the top view of the shape schematically illustrating the reactor device involved by one embodiment of the present invention.
Fig. 4 be to schematically illustrate in order to stress produced by core body in embodiment is evaluated to the impact that iron loss causes and The figure of the structure of the test portion used.
Fig. 5 is the curve illustrating the result being evaluated stress produced by core body to the impact that iron loss causes and obtain Figure.
Fig. 6 (a), (b) are to schematically illustrate the applying form to implementing, apply to core body external force in embodiment to make to iron loss The figure of the method that the impact become is evaluated.
Fig. 7 is to illustrate the knot being evaluated the applying form applying external force to core body to the impact that iron loss causes and obtain The curve chart of fruit.
Description of reference numerals:
100 reactor devices
10 core bodys
11a, 11b kink
12a, 12b line part
15 coils
20 reactor main bodys
30 housings
40 encapsulants
41a, 41b first encapsulant
42 second encapsulants
MP magnetic circuit
Detailed description of the invention
Hereinafter, embodiments of the present invention are described in detail.
Fig. 1 is the axonometric chart of the shape schematically illustrating the reactor device involved by one embodiment of the present invention.Such as Fig. 1 Shown in, reactor device 100 possesses: reactor main body 20, and it possesses under top view core body 10 in the form of a ring and is wound in core The coil 15 of body 10；House the housing 30 of reactor main body 20；And be filled between reactor main body 20 and housing 30 close Closure material 40.
Core body 10 is made up of press-powder core body, this press-powder core body possess the material comprising Magnaglo is carried out press molding and The powder compact obtained.Fig. 2 is the top view of the shape schematically illustrating the core body 10 that reactor device 100 is possessed.By press-powder core Body constitute core body 10 overlook under in the form of a ring, as in figure 2 it is shown, mark off the magnetic circuit MP of Guan Bi.Core body 10 has: have insertion Part in coil 15 and mark off two line parts 12a, 12b of magnetic circuit of linearity；And it is each with line part 12a, 12b From end arrange continuously and mark off two kinks 11a, 11b of the magnetic circuit of bending.Core body 10 shown in Fig. 2 is by a pressure Powder body is constituted, but is not limited to this.Can also be made up of multiple powder compacts.As such example, enumerate line part 12a, 12b And kink 11a, 11b are made up of independent powder compact respectively, and it is monolithically fabricated under top view core body in the form of a ring Example.
The kind of the Magnaglo constituting powder compact does not limit.The magnetic material constituting Magnaglo is roughly divided into knot Crystalloid magnetic material and noncrystalline magnetic material.
As long as the condition that crystalline magnetic material meets crystalline (is measured by common X-ray diffraction, obtains can be true Determine the diffraction spectrum in the degree of material category with clear and definite peak value) and be the bar of ferromagnetic, especially soft-magnetic body Part, does not the most limit concrete kind.As the concrete example of crystalline magnetic material, enumerate Fe-Si-Cr system alloy, the conjunction of Fe-Ni system Gold, Fe-Co system alloy, Fe-V system alloy, Fe-Al system alloy, Fe-Si system alloy, Fe-Si-Al system alloy, carbonyl iron and pure Ferrum.Above-mentioned crystalline magnetic material can be made up of a kind of material, it is also possible to is made up of multiple material.
As long as it is that amorphous condition (is measured by common X-ray diffraction, do not obtains at energy that noncrystalline magnetic material meets Enough determine the diffraction spectrum in the degree of material category with clear and definite peak value) and be ferromagnetic, especially soft-magnetic body Condition, does not the most limit concrete kind.As the concrete example of noncrystalline magnetic material, enumerate Fe-Si-B system alloy, Fe-P-C system Alloy and Co-Fe-Si-B system alloy.Above-mentioned noncrystalline magnetic material can be made up of a kind of material, it is also possible to by multiple Material is constituted.
If the Fe-P-C system alloy for the example as above-mentioned noncrystalline magnetic material specifically illustrates composition example, then enumerate Composition formula is by Fe100 atom %-a-b-C-x-y-z-tNiaSnbCrcPxCyBzSitRepresent and be 0 atom %≤a≤10 atom %, 0 atom % ≤ b≤3 atom %, 0 atom %≤c≤6 atom %, 6.8 atom %≤x≤10.8 atom %, 2.2 atom %≤y≤9.8 are former Sub-%, 0 atom %≤z≤4.2 atom %, the Fe base amorphous alloy of 0 atom %≤t≤7 atom %.At above-mentioned composition formula In, Ni, Sn, Cr, B and Si are arbitrary addition element.
In the case of employing noncrystalline magnetic material, compared with the situation using crystalline magnetic material, basic Trend is to reduce the iron loss of reactor device.On the other hand, due to containing magnetostriction constant than crystalline magnetic material Big material, therefore, possesses the pressure being made up of the powder compact of the Magnaglo comprising noncrystalline magnetic material at reactor device In the case of powder core body, the iron loss of reactor device is easily impacted by the cure shrinkage of curable constituent.Even if at this In the case of Zhong, in the case of the reactor device 100 involved by one embodiment of the present invention, owing to using multiple curable The encapsulant 40 of constituent solidification, and configure these encapsulants, therefore, curable in consistent manner with the shape of core body The cure shrinkage of constituent is difficult to impact iron loss.
The shape of Magnaglo is not defined, can be spherical can also be non-spherical.In the case of for non-spherical, Can be flakey, oval spherical, the such shape with shape anisotropy of droplet-like, needle-like, it is also possible to be special Not there is the unsetting shape of shape anisotropy.As the example of unsetting powder body, enumerate multiple globular powders to connect Mode combine or situation about combining in the way of other powder are imbedded in local.The shape of Magnaglo can be to manufacture magnetic The shape that the stage of property powder obtains, it is also possible to be the shape obtained by the Magnaglo produced is carried out secondary operations Shape.As the former shape, exemplify spherical, droplet-like, needle-like etc. spherical, oval, as the shape of the latter, exemplify scale Shape.
The size of Magnaglo is not the most defined.As carried out laser diffraction, scattering particle size distribution measuring time in Value footpath D50, exemplifies below more than 0.1 μm and 100 μm, it is sometimes preferred to be below more than 1 μm and 50 μm.
Powder compact preferably comprises the bonding component of the other materials making Magnaglo be bonded in contained by powder compact sometimes.Make For bonding component, generally use the material of insulating properties.Thereby, it is possible to improve the insulating properties as powder compact.As this insulating properties Material, they (in this specification, are referred to as " based on tree by the thermal decomposition residues exemplifying resin material and resin material Fat material and the composition that formed ".) etc. organic system material, inorganic based material etc..From the viewpoint of productivity etc., bonding component It is preferred for comprising the composition formed based on resin material.As resin material, exemplify acrylic resin, silicone resin, Epoxy resin, phenol resin, urea resin, melmac etc..The bonding component being made up of inorganic based material illustrates water outlet glass The glass based materials such as glass.Bonding component can be made up of a kind of material, it is also possible to is made up of multiple material.Bonding component can also It it is the mixture of organic system material and inorganic based material.
Powder compact is formed by press molding in the manner described above.The condition of this press molding is not defined.According to For formed powder compact material form and suitably set.As stressed concrete example, enumerate more than 0.1GPa and 10GPa with Under.Can heat when press molding, it is also possible to pressurize at normal temperatures.Can also be to the formed body after press molding Heat.By formed body is heated, deformation Magnaglo applied when press molding sometimes can be relaxed.Heating Condition is set properly according to the composition of formed body.As the concrete example of heating condition, enumerate with the temperature of 200 DEG C to 500 DEG C Degree keeps 10 minutes to 10 hours.
Coil 15 is by by the volume around line part 12a, 12b respectively by the winding line constituted by insulation-coated conductor Coiled and constitute.Conductor is suitable for using the metal material such as copper, copper alloy, insulation-coated in be suitable for using the resin such as enamel Based material.The section shape of winding line is not defined.Exemplify circle, ellipse, rectangle etc..Can be at the straight line of core body 10 Convolute coil 15 in the entire scope of portion 12a, 12b, it is possible to have unwound part.
Housing 30 has the container-like shape of an opening, houses reactor main body 20 therein.Housing 30 interior Portion can also use following structure: has the identical sag and swell of the shape with reactor main body 20 and makes reactor main body 20 difficult To move inside housing 30.The one side of the opening of housing 30 can also be covered partly.The constituent material of housing 30 not by Limit.It is preferably the material that exothermicity is excellent, from this viewpoint, uses the metal material such as aluminum, aluminium alloy aptly.
Encapsulant 40 is between reactor main body 20 and housing 30, and reactor main body 20 is fixed on housing 30. In the reactor device 100 involved by one embodiment of the present invention, encapsulant 40 possesses: be positioned at kink 11a, 11b And first encapsulant 41a, 41b between housing 30；And be positioned at least some of of line part 12a, 12b and housing 30 it Between the second encapsulant 42.And, the Young's modulus of first encapsulant 41a, 41b is than the poplar of described second encapsulant 42 Family name's modulus is low.It should be noted that as it is shown on figure 3, in reactor device 100, the second encapsulant 42 is positioned at line part Between entirety and the housing 30 of 12a, 12b.
So, by make to be positioned at the surrounding of kink 11a, 11b of core body encapsulant (the first encapsulant 41a, 41b) different from the encapsulant of the surrounding being positioned at line part 12a, 12b (the second encapsulant 42), it is possible to obtain following effect Really.
That is, different from line part 12a, 12b due to kink 11a, 11b and have complexity shape, therefore, curved being positioned at When the curable constituent of the surrounding of folding part 11a, 11b shrinks, become to the direction of kink 11a, 11b externally applied forces and comprise Shear the such direction of core body interior multi-direction.Therefore, even if little to kink 11a, 11b externally applied forces, the most easily increase Add the iron loss of the reactor device possessing core body.
To this, set by being pointed to the encapsulant (first encapsulant 41a, 41b) of the surrounding of kink 11a, 11b Relatively low Young's modulus, thus be difficult to during cure shrinkage apply external force to kink 11a, 11b, it is possible to suppress because first is close The cure shrinkage of closure material 41a, 41b and the increase of the iron loss of reactor device 100 that causes.
The concrete numerical value of the Young's modulus of first encapsulant 41a, 41b is not defined.In view of kink 11a, 11b Shape and composition, for forming the characteristic etc. of curable constituent of first encapsulant 41a, 41b, be suitably set as energy The impact that the iron loss of reactor device 100 is caused by enough reductions.If carrying out the most limited illustration, then the first encapsulant The Young's modulus of 41a, 41b is preferably below 100MPa, more preferably below 50MPa, especially preferably below 10MPa.From fall From the viewpoint of the low impact that the iron loss of reactor device 100 is caused, do not set the Young mould of first encapsulant 41a, 41b The lower limit of amount.In the case of the Young's modulus of first encapsulant 41a, 41b is too low, even if improving second in the following manner The Young's modulus of encapsulant 42, also occasionally there are the reactor main body 20 trend relative to the fixing destabilization of housing 30. Therefore, the Young's modulus of first encapsulant 41a, 41b is preferably more than 0.1MPa, the most more preferably more than 1MPa sometimes.
It is difficult to reactor device owing to being positioned at the cure shrinkage of the curable constituent of the surrounding of line part 12a, 12b The iron loss of 100 impacts, therefore, by improving the Young's modulus of the second encapsulant 42, it is possible at this part reliably Carry out reactor main body 20 fixing relative to housing 30.
The concrete numerical value of the Young's modulus of the second encapsulant 42 is not defined.Shape in view of line part 11a, 11b Shape and composition, for forming the characteristic etc. of the curable constituent of the second encapsulant 42, being suitably set as can be reliably Reactor main body 20 is fixed on housing 30.If carrying out the most limited illustration, then the Young mould of the second encapsulant 42 Amount is preferably more than 1GPa, more preferably more than 5GPa, especially preferably more than 20GPa.The Young mould of the second encapsulant 42 The lower limit of amount is not defined.In the case of the Young's modulus of the second encapsulant 42 is too high, by reactor device 100 institute Vibration etc. that is that produce or that be applied in, occasionally there are the trend easily producing crack in the second encapsulant 42.Therefore, The Young's modulus of two encapsulants 42 is preferably below 100GPa, the most more preferably below 70GPa sometimes.
As long as the composition of the composition of first encapsulant 41a, 41b and the second encapsulant 42 meets and above-mentioned poplar respectively The condition that family name's modulus is relevant, is defined the most especially.From the viewpoint of left-hand seat easiness, operability height, preferably first is close Closure material 41a, 41b and the second encapsulant 42 comprise resin system material.In this case, it is used for forming a certain encapsulant Curable constituent also become the material containing curable resin.As this resin material, exemplify: epoxy resin, silicon The thermosetting resins such as ketone resin, phenol resin, melmac；And the tool such as polyphenylene sulfide (PPS), liquid crystal polymer (LCP) There is the thermoplastic resin of thermostability (softening point is high)；The cross-linking agent such as isocyanates system are added in the thermoplastic resins such as polyester (PE) And improve the material etc. of curable.It addition, curable constituent can also be containing by aluminium oxide, silicon dioxide, silicon nitride, nitrogen Change the filler that the inorganic based materials such as aluminum, boron nitride, carborundum are constituted.By making the curable constituent of such filler Amount changes, it is possible to adjust the Young's modulus of encapsulant 40.
As first encapsulant 41a, 41b not formed the concrete example limited, enumerate the thermosetting as softer Property resin silicone resin be used as curable resin main component and by aluminium oxide be used as filler example.As not to The concrete example that the composition of two encapsulants 42 limits, enumerates and the epoxy resin of the thermosetting resin as relatively hard is used as solidification Property resin main component and by aluminium oxide be used as filler example.
As being provided with the electric/electronic device of reactor device 100, exemplify the conversion being assembled with reactor device 100 Device.The transducer of the buck especially carrying out voltage in hybrid motor vehicle, electric motor vehicle is on-vehicle parts, because of This, especially require high reliability to the side being easily subject to the external force such as vibration.Reactance involved by one embodiment of the present invention In device device 100, the cure shrinkage of the curable constituent for forming encapsulant 40 is difficult to the ferrum to reactor device 100 Damage impacts, and therein, reactor main body 20 is firmly fixed at housing 30.Even if it addition, to reactor device In the case of 100 are applied with external force, owing to being easily subject to external force image and damnous kink 11a, 11b, it is positioned at it The Young's modulus of encapsulant (first encapsulant 41a, 41b) around is low, therefore, outside reactor device 100 applies Power is difficult to be delivered to kink 11a, 11b.Therefore, the reactor device 100 involved by one embodiment of the present invention is suitable for using Make the transducer of vehicle-mounted purposes.
[embodiment]
Hereinafter, utilize embodiment etc., further the present invention is specifically illustrated, but the scope of the present invention is not limited to These embodiments etc..
(1) making of Fe base amorphous alloy powder
With composition by Fe74.28 atom %Cr1.56 atom %P8.78 atom %C2.62 atom %B7.57 atom %Si5.19 atom %The mode constituted weighs former Material, utilizes water atomization to make the powder of noncrystalline magnetic material.Use Ji Zhuan company manufacture " wheat strange gram particle degree divides Cloth determinator MT3300EX ", the particle size distribution of the powder of obtained noncrystalline magnetic material is measured according to volume distributed median, 50% cumulative path (Second Intermediate Value footpath d2) D50 in the cumulative particle size distribution of volume reference is 5～20 μm.
(2) making of pelletizing
Magnaglo 97.7 Quality Mgmt Dept that the above-mentioned powder by noncrystalline magnetic material is constituted and by acrylic acid tree Insulating properties binding material 2.0 Quality Mgmt Dept, lubricant 0.3 Quality Mgmt Dept that fat is constituted are mixed in and obtain slip as the water of solvent.
Obtained slip is pulverized after the drying, the sieve using mesh to be 300 μm, obtain by having passed through 300 μm The pelletizing that the powder of mesh is constituted.
(3) compression molding
Obtained pelletizing is filled in mould, carries out press molding with face pressure 1.77Gpa, obtain that there is external diameter The ring-type formed body of 20.7mm × internal diameter 12.4mm × thickness 6.8mm.And it is filled in another mould, presses 1.77Gpa with face Carry out press molding, obtain the formed body with the square column shape that bottom surface is 10mm × 10mm and height is 48mm.
(4) heat treatment
Obtained formed body is placed in the stove of nitrogen stream environment respectively, by in-furnace temperature from room temperature (23 DEG C) with 10 DEG C/min programming rate be heated to 370 DEG C, and at such a temperature keep one hour, then, carry out in stove, be cooled to room temperature Heat treatment.So, ring-type powder compact and bar-shaped powder compact are obtained.
The mensuration of (test example 1) iron loss Pcv
As shown in Figure 4, the annular core element being made up of the ring-type powder compact made by the way is installed end face (mensuration direction is thickness direction and circumferencial direction) strain gauge at totally three at (measure direction be radially), side two at one, The stress putting on annular core element can be measured based on the signal from these strain gauges.Will be to this annular core element respectively one Secondary side winding 15 circle, the secondary side winding 10 coating copper cash of circle and the loop coil that obtains and BH analyser (Yan Qi communication equipment company " SY-8218 " manufactured) connect, it is possible to measure iron loss Pcv (unit: kW/m3).In this condition, close at the most maximum magnetic flux Degree Bm is 100mT, mensuration frequency is mensuration iron loss Pcv under conditions of 100kHz, as reference value Pcv0 of iron loss.
In can housing toroidal container, configure loop coil, the curable constituent of epoxy system resin will be comprised (also referred to as " curable constituent I ".) or comprise the curable constituent of silicon system resin (also referred to as " curable constituent II ".) In injection container, and container entirety is heated and makes resin solidify.When resin have cured, based on from three The signal of strain gauge, calculates the mean stress applied to annular core element.As a result of which it is, confirm the kind because of resin, press-powder The particle diameter distributions of body etc. are different and apply different compression stresses.Basic trend is, low the consolidating of Young's modulus at solidfied material In the case of the property changed constituent II, compression stress is low, and (stress value is negative value and close to zero.), high in the Young's modulus of solidfied material Curable constituent I in the case of, (stress value is negative value and away from zero to become higher compression stress.).It addition, effectively Peakflux density Bm is 100mT, measure frequency is to determine toroidal iron loss Pcv under conditions of 100kHz.According to To iron loss Pcv obtain the above-mentioned iron loss increment rate relative to reference value Pcv0.Basic trend is, at the Young of solidfied material In the case of the curable constituent II that modulus is low, the increment rate of iron loss Pcv is low, the curable that Young's modulus at solidfied material is high In the case of constituent I, the increment rate of iron loss Pcv uprises.
At the side convolute coil of the press-powder core body being made up of above-mentioned bar-shaped powder compact, and with the end of My World in future The mode of the end face that the magnetic flux in face guides the opposing party installs ferrite yoke, induction apparatus and (the rugged communication of rock of BH analyser that will obtain " SY-8218 " that machine company manufactures) connect such that it is able to measure iron loss Pcv (unit: kW/m3).In this condition, ferrum is measured Damage Pcv and be used as reference value Pcv0 of iron loss.
Above-mentioned induction apparatus is installed on cupping machine in the way of the both ends of the surface of press-powder core body can be compressed, make Put on the compression stress change of the both ends of the surface of press-powder core body and determine iron loss Pcv.As a result of which it is, when putting on press-powder core body When the compression stress of both ends of the surface becomes big, the increment rate of iron loss also uprises.
Fig. 5 illustrates above result.As it is shown in figure 5, for the measurement result of ring-type press-powder core body and for bar-shaped The measurement result of press-powder core body the trend that the increment rate of iron loss uprises when compression stress produced by core body increases all is shown, The above results entirety can be approximately substantial linear (Fig. 5 dotted line).
(test example 2)
Identical with test example 1, by manufacturing the above-mentioned toroid possessing the annular core element being made up of ring-type powder compact Circle, and be connected with BH analyser (" SY-8218 " that Yan Qi communication equipment company manufactures) and can determine iron loss Pcv (unit: kW/m3).In this condition, effective peakflux density Bm be 100mT, measure frequency be 100kHz under conditions of determine Iron loss Pcv is used as reference value Pcv0 of iron loss.
As shown in (a) or (b) of Fig. 6, loop coil is configured at cupping machine, is respectively directed at (a) with radially Apply the situation (annulus load) that configures of mode of external force and situation that (b) configures in the way of through-thickness applies external force (end face load), apply while external force with above-mentioned condition (effective peakflux density Bm as 100mT, measure frequency and be 100kHz) determine iron loss Pcv, and how the increment rate determining iron loss changes according to institute's externally applied forces.
As a result of which it is, as it is shown in fig. 7, confirm impact that the increment rate of iron loss causes by the external force situation at annulus load Under, bigger than the situation of end face load about 10 times.
According to above result, confirming in press-powder core body, linearity magnetic circuit is such has simple shape marking off At the part of shape, the increase of external force will not make the degree that iron loss increases become big, and has the magnetic circuit marking off bending is such At the part of complicated shape, the increase of external force easily makes iron loss increase.Therefore, as reactor device involved in the present invention that Sample, by making the local shape of the Young's modulus and core body that are positioned at the encapsulant of reactor main body correspondingly change, it is possible to press down The iron loss making the reactor device caused because of the cure shrinkage of the curable constituent for forming encapsulant increases.
Industrial applicibility
The reactor device of the present invention can be used as transformator, chokes aptly as the commutator assemble of vehicle-mounted purposes The induction apparatuss such as coil.

Claims (10)

1. a reactor device, it possesses:
Reactor main body, it possesses under top view core body in the form of a ring and is wound in the coil of described core body；
Housing, it houses described reactor main body；And
Encapsulant, it is filled between described reactor main body and described housing,
Described reactor device is characterised by,
Described core body is made up of press-powder core body, and this press-powder core body possesses the pressure to the material press molding comprising Magnaglo Powder body,
Described core body has: two line parts, and said two line part has the part being inserted in described coil, and marks off The magnetic circuit of linearity；And two kinks, said two kink is arranged continuously with each end of described line part, and draws Separate the magnetic circuit of bending,
Described encapsulant possesses: the first encapsulant between described kink and described housing；And it is positioned at described The second encapsulant between at least some of and described housing of line part,
The Young's modulus of described first encapsulant is lower than the Young's modulus of described second encapsulant.
Reactor device the most according to claim 1, it is characterised in that
Described first encapsulant and described second encapsulant comprise resin system material.
Reactor device the most according to claim 1 and 2, it is characterised in that
Described second encapsulant comprises filler.
Reactor device the most according to claim 1 and 2, it is characterised in that
The Young's modulus of described first encapsulant is below 50MPa.
Reactor device the most according to claim 1 and 2, it is characterised in that
The Young's modulus of described second encapsulant is more than 5GPa.
Reactor device the most according to claim 1 and 2, it is characterised in that
Described Magnaglo comprises from being made up of Fe-Si-B system alloy, Fe-P-C system alloy and Co-Fe-Si-B system alloy The powder of one or more the noncrystalline magnetic material selected in group.
Reactor device the most according to claim 6, it is characterised in that
Described noncrystalline magnetic material is made up of Fe-P-C system alloy.
Reactor device the most according to claim 1 and 2, it is characterised in that
Described powder compact contains the bonding component of the other materials making described Magnaglo be bonded in contained by described powder compact.
Reactor device the most according to claim 8, it is characterised in that
Described bonding component comprises the composition formed based on resin material.
10. an electric/electronic device, it is characterised in that
Described electric/electronic device is provided with the reactor device described in claim 1 or 2.
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