EP3633699B1 - Reactor and method of manufacturing the same - Google Patents

Reactor and method of manufacturing the same Download PDF

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Publication number
EP3633699B1
EP3633699B1 EP19199511.7A EP19199511A EP3633699B1 EP 3633699 B1 EP3633699 B1 EP 3633699B1 EP 19199511 A EP19199511 A EP 19199511A EP 3633699 B1 EP3633699 B1 EP 3633699B1
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European Patent Office
Prior art keywords
coil
wire
lateral surface
heat radiation
reactor
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EP19199511.7A
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German (de)
English (en)
French (fr)
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EP3633699A1 (en
Inventor
Kazumi Serizawa
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Toyota Motor Corp
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Toyota Motor Corp
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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
    • H01F27/28—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
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/08—Cooling; Ventilating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/02—Fixed inductances of the signal type  without magnetic core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • 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
    • 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
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/263—Fastening parts of the core together
    • 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
    • H01F27/2823—Wires
    • 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
    • H01F27/2847—Sheets; Strips
    • 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
    • H01F27/2876—Cooling
    • 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
    • H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other 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
    • H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306—Fastening or mounting coils or windings on core, casing or other 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
    • H01F27/323—Insulation between winding turns, between winding layers
    • 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
    • H01F27/327—Encapsulating or impregnating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/061—Winding flat conductive wires or sheets
    • H01F41/063—Winding flat conductive wires or sheets with insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • H01F41/122—Insulating between turns or between winding layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/06—Insulation of windings

Definitions

  • the invention relates to a reactor and a method of manufacturing the reactor.
  • the invention relates to a reactor having a cooler that is opposed to a flat lateral surface of a coil across an insulating heat radiation layer, and a method of manufacturing the reactor.
  • a reactor having a cooler that is opposed to one lateral surface of a coil, which has been wound into the shape of a prism, across an insulating heat radiation layer (e.g., Japanese Patent Application Publication No. 2016-92313 ( JP 2016-92313 A )).
  • the insulating heat radiation layer is adopted to provide assistance in transmitting heat from the coil to the cooler.
  • Each of portions of a wire constituting the coil is covered with an insulating film so as not to short-circuit to the portions of the wire that are adjacent to the portion of the wire in a pitch direction.
  • the insulating film lowers the efficiency of heat transmission from the coil to the insulating heat radiation layer.
  • the insulating film has been removed from that one of lateral surfaces of the coil which is opposed to the insulating heat radiation layer.
  • the insulating heat radiation layer provides assistance in transmitting heat from the coil (the portions of the wire) to the cooler, and insulates the exposed portions of the wire of the coil from the cooler.
  • each surface of the coil that is parallel to an axis thereof will be referred to as "the lateral surface of the coil”. Further reactors and methods of manufacturing thereof are disclosed in US 9,449,751 B2 , JP 2018-82129 and JP 2017-50334 .
  • the distance between the coil and the cooler becomes short, so that the efficiency of heat transmission becomes high.
  • the degree of flatness of each of the lateral surfaces of the coil is high (when each of the lateral surfaces of the coil is coarse)
  • the distances between various spots of the lateral surface and the cooler vary. That is, the distance between the winding located closest to the cooler and the winding located furthest from the cooler becomes long.
  • the thickness of the insulating heat radiation layer needs to be increased.
  • the thermal resistance of the insulating heat radiation layer increases as the thickness thereof increases. Therefore, the efficiency of heat transmission falls at the spots where the insulating heat radiation layer is thick.
  • each of the lateral surfaces of the coil is formed of an aggregate of the portions of the wire that are aligned in an axial direction of the coil.
  • the degree of flatness becomes relatively high.
  • JP 2016-92313 A JP 2016-92313 A
  • the degree of flatness may be evaluated as, for example, a maximum inclination-type degree of flatness.
  • the maximum inclination-type degree of flatness is represented by a distance between two parallel ideal planes when a plane to be measured is sandwiched between the ideal planes.
  • each of "the ideal planes” means a perfect plane with no undulations as expressed by a mathematical equation about planes.
  • the similarity of the plane to be measured to the ideal plane increases as the degree of flatness decreases.
  • the degree of flatness is evaluated while ignoring the roundness of transverse sections of the portions of the wire.
  • a reactor according to the invention is defined in claim 1.
  • the second lateral surface may be a curved surface that extends from one edge of the first lateral surface to the other edge thereof, or may include a plurality of flat lateral surfaces. In the latter case, the coil has a polygonal prism shape.
  • the lowered degree of flatness of the first lateral surface that is opposed to the cooler can be maintained by allowing the degree of flatness of the second lateral surface different from the first lateral surface that is opposed to the cooler to be high.
  • the variation in the thickness of the insulating heat radiation layer decreases.
  • heat is uniformly transmitted from various spots of the first lateral surface to the cooler, and the efficiency of heat transmission from the coil to the cooler is enhanced.
  • the insulating heat radiation layer can be reduced in thickness.
  • the coil may include the wire that is a rectangular wire wound in an edgewise manner.
  • a gap may be provided between portions of the wire that are adjacent to each other. Gaps are ensured among the exposed surfaces of the portions of the wire that are aligned in a pitch direction. Conductors are exposed on the exposed surfaces. Therefore, when the exposed surfaces that are adjacent to each other are close to each other, short-circuiting may be caused. Since the gaps are ensured among the exposed surfaces that are aligned in the pitch direction, the exposed surfaces that are adjacent to each other in the pitch direction can be prevented from short-circuiting to each other.
  • a thickness of the wire in an inner portion of the coil may be larger than a thickness of the wire in an outer portion of the coil .
  • a thickness of the wire at a corner portion of the coil that is adjacent to the first lateral surface may be larger on an inner peripheral side of the coil than on an outer peripheral side of the coil as viewed in an axial direction of the coil.
  • a space between portions of the wire that are adjacent to each other in a pitch direction may be filled with an insulating material.
  • conductive dust or the like is stuck near the exposed surfaces of the portions of the wire, the exposed surfaces that are adjacent to each other in the pitch direction may short-circuit to each other.
  • a surface of the cooler which is in contact with the insulating heat radiation layer may be conductive, and the insulating heat radiation layer may include a ceramic board.
  • the insulating heat radiation layer may include silicon and a ceramic board.
  • a slit may be provided in a surface of a portion of the wire, the surface of the portion of the wire being not covered with the insulating film.
  • a second aspect of the invention relates to a method of manufacturing the above-mentioned reactor.
  • the method includes winding the wire, from which the insulating film has not been removed, to form the coil having the first lateral surface and the second lateral surface, and removing the insulating film by polishing the first lateral surface such that the degree of flatness of the first lateral surface becomes lower than the degree of flatness of the second lateral surface.
  • a space between portions of the wire that are adjacent to each other in a pitch direction may be filled with an insulating material.
  • FIG. 1 is a perspective view showing the reactor 2.
  • the reactor 2 is a passive element having a core 20 around which a coil 5 is wound.
  • the core 20 and the coil 5 are covered with a resin cover 3, and are invisible.
  • the reactor 2 is used for, for example, a chopper-type step-up converter that is mounted in, for example, an electric vehicle.
  • a running motor of the electric vehicle can output several tens of kilowatts, and an electric power of several tens of kilowatts flows through the coil 5 of the reactor 2.
  • the coil 5, through which a large electric power flows, generates a large amount of heat. Therefore, the reactor 2 is equipped with a cooler 6.
  • FIG. 1 is a perspective view showing the reactor 2.
  • the reactor 2 is a passive element having a core 20 around which a coil 5 is wound.
  • the core 20 and the coil 5 are covered with a resin cover 3, and are invisible.
  • the reactor 2 is used for, for example, a chopper-type step
  • FIG. 2 is a perspective view showing the reactor 2 from which the resin cover 3 and the core 20 have been removed.
  • FIG. 3 is a sectional view taken along a line III-III of FIG. 1 .
  • the core 20 is depicted by a virtual line.
  • the coil 5 is formed by winding a wire 4 into the shape of a prism.
  • the coil 5 is obtained by winding the wire 4, which are rectangular, in an edgewise manner.
  • edgewise refers to a winding method in which a rectangular wide surface is oriented in an axial direction of the coil.
  • the axial direction of the coil is an extending direction of an axis of the coil, and is an X-direction in a coordinate system in the drawing.
  • the coil 5 assumes the shape of a quadrangular prism, and has four flat lateral surfaces.
  • Each of "the flat lateral surfaces of the coil 5" means a flat surface parallel to an axis Ca of the coil 5.
  • the flat lateral surface oriented in a +Z-direction in the coordinate system in the drawing will be referred to as an upper surface 5a
  • the flat lateral surface oriented in a -Z-direction will be referred to as a lower surface 5d.
  • the flat lateral surface oriented in a +Y-direction will be referred to as a right lateral surface 5b
  • the flat lateral surface oriented in a -Y-direction will be referred to as a left lateral surface 5c.
  • the cooler 6 is opposed to the lower surface 5d of the coil 5 across the insulating heat radiation layer 12.
  • the lower surface 5d of the coil 5 is thermally in contact with the cooler 6 across the insulating heat radiation layer 12.
  • a lower surface of the core 20 is thermally in contact with the cooler 6 via an insulating heat radiation layer 13.
  • a plurality of fins 7 are provided on a lower surface of the cooler 6.
  • the lower surface of the cooler 6 faces a coolant flow passage, and the fins 7 are exposed to liquid coolant.
  • the insulating heat radiation layers 12 and 13 are made of silicon rubber exhibiting resistance to high temperatures and flexibility. Both the coil 5 and the cooler 6 are made of metal. Therefore, even when the coil 5 and the cooler 6 are in direct contact with each other, there is created a gap therebetween. Thus, the soft insulating heat radiation layer 12 is sandwiched between the coil 5 and the cooler 6, so as to provide assistance in transmitting heat from the coil 5 to the cooler 6.
  • the insulating heat radiation layer 13 also has a similar purpose. It should be noted, however, that since the coil 5 generates heat, the efficiency of heat transmission from the lower surface 5d of the coil 5 to the cooler 6 particularly influences the cooling performance of the coil 5. Therefore, the efficiency of heat transmission from the coil 5 to the insulating heat radiation layer 12 is desired to be high.
  • One method of enhancing the efficiency of heat transmission from the coil 5 to the insulating heat radiation layer 12 is to reduce the degree of flatness of the lower surface 5d of the coil 5.
  • the degree of flatness of the lower surface 5d is high, when the lower surface 5d is pressed against the insulating heat radiation layer 12, the variation in the gap between the lower surface 5d and the cooler 6 becomes large.
  • the variation in the gap is large, there are spots where the insulating heat radiation layer 12 has a large thickness.
  • the thermal resistance of the insulating heat radiation layer 12 increases as the thickness thereof increases. Therefore, the efficiency of heat transmission deteriorates at the spots where the insulating heat radiation layer 12 is thick.
  • the variation in the gap between the lower surface 5d and the cooler 6 becomes small.
  • the thickness of the insulating heat radiation layer 12 is uniform, heat is uniformly transmitted from the entire lower surface 5d to the insulating heat radiation layer 12, and the efficiency of heat transmission is enhanced.
  • the variation in the coil surface as the first lateral surface has become small, so the insulating heat radiation layer 12 can be reduced in thickness.
  • FIG. 4 is a view schematically showing part of a section of the coil 5.
  • An upper side in the drawing corresponds to an inner side of the coil, whereas a lower side in the drawing corresponds to an outer side of the coil.
  • the coil 5 is obtained by winding the rectangular wire 4 in an edgewise manner.
  • the wire 4 is made of copper, which exhibits small internal resistance and high thermal conductivity. In the case of edgewise winding, the rectangular wire 4 is forcefully bent, so the position of the winding of each pitch is unlikely to remain the same due to the occurrence of springback or the like. As shown in FIG.
  • a plane S1 (an ideal plane S1) is a plane that is in contact with a winding 4 in, which is located on an innermost side of the coil, in an outer portion of the coil.
  • a plane S2 (an ideal plane S2) is a plane that is in contact with a winding 4 out, which is located on an outermost side of the coil, in an outer portion of the coil.
  • the plane S1 and the plane S2 are parallel to each other.
  • a distance R between the ideal planes S 1 and S2 represents the degree of flatness of the lateral surface of the coil. That is, “that the degree of flatness of the lateral surface of the coil is low” means that there is a short distance between the plane that is in contact with the winding located on the innermost side of the coil in an outer portion of the coil and the plane that is in contact with the winding located on the outermost side of the coil in an outer portion of the coil.
  • FIG. 5 is a front view showing the coil 5.
  • FIG. 5 schematically shows the degree of flatness of each of the lateral surfaces of the coil 5.
  • a degree Ra of flatness of the upper surface 5a is represented by a distance between the ideal plane S1 that is in contact with a most recessed spot of the upper surface 5a and the ideal plane S2 that is parallel to the ideal plane S1 and that is in contact with a most protrusive spot of the upper surface 5a.
  • the position of the winding in the radial direction of the coil of each pitch varies, so the degree Ra of flatness is relatively high.
  • a degree Rb of flatness of the right lateral surface 5b, a degree Rc of flatness of the left lateral surface 5c, and a degree Rd of flatness of the lower surface 5d are also approximately equal to the degree Ra of flatness.
  • the rectangular wire 4 exhibits high rigidity, so there is a limit to making the degrees of flatness of all the lateral surfaces low.
  • a large stress is applied to various spots of the coil 5. This is because the stress emerges in the form of springback, and the degrees of flatness that have once been made low are increased again.
  • the degree Rd of flatness of the lower surface 5d that is opposed to the insulating heat radiation layer 12 is made low, and instead, the degrees of flatness of the other flat lateral surfaces (the upper surface 5a, the right lateral surface 5b, and the left lateral surface 5c) are allowed to be relatively high.
  • the degree Rd of flatness of the lower surface 5d that is in contact with the insulating heat radiation layer 12 is made lower than the degrees Ra, Rb, and Rc of flatness of the other lateral surfaces.
  • the stress applied to the coil 5 becomes small, and the amount of springback also becomes small. Accordingly, the low degree of flatness of the lower surface 5d can be maintained, and the efficiency of heat transmission from the lower surface 5d to the insulating heat radiation layer 12 is enhanced.
  • FIG. 6 is view showing part of a section taken along a line VI-VI of FIG. 3 .
  • the section of FIG. 6 corresponds to a section obtained by cutting the coil 5 along a plane containing the axis Ca (see FIG. 3 ) of the coil 5.
  • the axis Ca extends parallel to the X-axis of the coordinate system in the drawing.
  • FIG. 6 is a partial sectional view of a region constituting the lower surface 5d of the coil 5. Besides, FIG. 6 shows only part of the direction of the axis Ca of the coil 5.
  • Each of the portions of the wire 4 of the coil 5 is covered with an insulating film 41 to prevent short-circuiting to the portion of the wire 4 of an adjacent pitch.
  • a reference numeral 4 (the wire 4) and a reference numeral 41 (the insulating film 41) are assigned only to the rightmost winding, and no reference numeral is assigned to the other windings (the other portions) of the wire.
  • the insulating film 41 is typically an enameled film.
  • the wire 4 is made of a metal exhibiting high thermal conductivity, such as copper or the like.
  • the thermal conductivity of the insulating film 41 is not as high as that of a metal such as copper or the like.
  • the insulating film has been removed from those regions of the portions of the wire 4 which are in contact with the insulating heat radiation layer 12, with a view to enhancing the efficiency of heat transmission from the coil 5 to the insulating heat radiation layer 12.
  • exposed surfaces 4a An aggregate of the exposed surfaces 4a of the portions of the wire 4 constitutes the lower surface 5d of the coil 5.
  • each of the exposed surfaces 4a of the portions of the wire 4 is a surface corresponding to the lower surface 5d of the coil 5.
  • a reference symbol 4a is assigned only to one of the outer lateral surfaces.
  • the insulating film is removed through polishing.
  • the portions of the wire 4 are also partially flattened through polishing. Therefore, the exposed surfaces 4a are flat.
  • the insulating film 41 which forms a surface corresponding to the lower surface 5d of the portions of the wire 4, has been removed, and the copper portions of the wire 4 are thus in direct contact with the insulating heat radiation layer 12. Therefore, the efficiency of heat transmission from the portions of the wire 4 (the coil 5) to the insulating heat radiation layer 12 is enhanced.
  • the following two features contribute towards enhancing the efficiency of heat transmission from the coil 5 to the insulating heat radiation layer 12.
  • the degree Rd of flatness of the lower surface 5d that is in contact with the insulating heat radiation layer 12 of the coil 5 is low.
  • the insulating film 41 has been removed from the portions of the wire 4 on the lower surface 5d.
  • one of the exposed surfaces 4a and the exposed surface 4a of a pitch adjacent thereto are spaced apart from each other by a gap Gh, and do not short-circuit to each other.
  • the gap Gh is slightly larger than the double of the thickness of the insulating film 41.
  • FIG. 7 is a sectional view showing a section of a coil of a reactor 2a according to a first modification example.
  • the section of FIG. 7 corresponds to the section of FIG. 6 . That is, FIG. 7 shows a shape of the section of portions of the wire 104 obtained by cutting those regions of the portions of the wire 104 which are in contact with the insulating heat radiation layer 12 along a plane containing an axis of the coil.
  • the wire 104 is a rectangular wire, and is wound in an edgewise manner.
  • the insulating film 41 has been removed from the portions of the wire 104 constituting the coil 5, on the lower surface 5d of the coil 5 that is in contact with the insulating heat radiation layer 12.
  • Surfaces from which the insulating film 41 has been removed will be referred to as exposed surfaces 104a.
  • a sectional shape of each of the portions of the wire 104 obtained by cutting those regions of the portions of the wire 104 which are in contact with the insulating heat radiation layer 12 along a plane containing an axis of the coil 5 is tapered toward the outer side of the coil.
  • a gap is provided between portions of the wire 104 that are adjacent to each other in an outer portion of the coil 5.
  • the section of each of the portions of the wire 104 is tapered toward the outer side of the coil, so the distance (the gap Gh) between the exposed surfaces 104a that are adjacent to each other in the pitch direction is longer than in the case of the embodiment. Since the gap Gh becomes long, the exposed surfaces 104a that are adjacent to each other can be more reliably prevented from short-circuiting to each other.
  • the insulating heat radiation layer 12 insulates the exposed metal of the portions of the wire 4 from the cooler 6. As shown in FIG. 4 , when the degree of flatness of each of the lateral surfaces of the coil 5 is high, there is a large difference between the winding 4out located closest to the cooler 6 and the winding 4in located furthest from the cooler 6. When there is a large difference between the winding 4out located closest to the cooler 6 and the winding 4in located furthest from the cooler 6, the thickness of the insulating heat radiation layer 12 needs to be increased to ensure contact with all the portions of the wire.
  • the insulating heat radiation layer 12 When the insulating heat radiation layer 12 has a large thickness, a fissure is likely to be created in the inside of the insulating heat radiation layer 12, in addition to a fall in the efficiency of heat transmission. When a fissure is created, air enters the fissure to cause a further fall in the efficiency of heat transmission.
  • the insulating heat radiation layer 12 is held in a pressurized state between the coil 5 and the cooler 6. Therefore, after long-term use, a fissure may be created in the insulating heat radiation layer 12 due to time degradation.
  • the temperature of the coil 5 repeatedly rises due to heat generation and falls due to cooling. This thermal cycle also accelerates time degradation of the insulating heat radiation layer 12.
  • the possibility of a fissure being created increases as the thickness of the insulating heat radiation layer 12 increases. In the reactor 2 according to the embodiment, the insulating heat radiation layer 12 can be made thin, so the possibility of a fissure being created can be made low.
  • FIG. 8 is a sectional view showing a section of a coil of a reactor 2b according to a second modification example.
  • the section of FIG. 8 corresponds to the section of FIG. 6 . That is, FIG. 8 shows a shape of a section of each of portions of the wire 204 obtained by cutting that region of each of the portions of the wire 204 which is in contact with the insulating heat radiation layer 12 along a plane containing an axis of the coil.
  • the wire 204 is a rectangular wire, and is wound in an edgewise manner.
  • a thickness Wa of the wire 204 in an inner portion of the coil is larger than a thickness Wb of the wire 204 in an outer portion of the coil.
  • the thickness of the wire 204 means a width of a conductor region of the wire 204 in an axial direction of the coil (the X-direction in the drawing).
  • that region of the insulating film 41 which is in contact with the insulating heat radiation layer 12 and which is located in an outer portion of the coil has a large thickness
  • that region of the insulating film 41 which is not in contact with the insulating heat radiation layer 12 and which is located in an inner portion of the coil has a small thickness.
  • the large gap Gh can be ensured between one of exposed surfaces 204a of the wire 204 and another exposed surface 204a that is adjacent thereto in the pitch direction.
  • the large gap Gh more reliably prevents the exposed surfaces 204a that are adjacent to each other from short-circuiting to each other.
  • FIG. 9 is a sectional view showing a section of a reactor 2c according to a third modification example.
  • the sectional view of FIG. 9 corresponds to the sectional view of FIG. 3 .
  • the wire 304 of the reactor 2c according to the third modification example is a rectangular wire, and is wound in an edgewise manner.
  • a coil corner portion that is adjacent to the lower surface 5d is thicker on an inner peripheral side of the coil than on an outer peripheral side of the coil, as viewed in a direction of the axis Ca of the coil 5.
  • Each of ranges indicated by broken lines Ar in FIG. 9 (areas Ar) indicates an area of the coil corner portion adjacent to the lower surface 5d on the inner peripheral side of the coil.
  • each of the areas Ar can also make it possible to increase the gap between the adjacent exposed surfaces of the portions of the wire 304 corresponding to the lower surface 5d of the coil. By increasing the gap between the exposed surfaces that are adjacent to each other in the pitch direction, the exposed surfaces can be more reliably prevented from short-circuiting to each other.
  • the coil 5 is obtained by winding the rectangular wire 304 in an edgewise manner into the shape of a quadrangular prism.
  • a jig is placed on inner sides of corner portions of the quadrangular prism to bend the wire 304.
  • the wire 304 is bent while being pressed hard against the jig.
  • the regions of the areas Ar can be plastically deformed, and the thickness of conductor regions of the wire 304 can be increased.
  • FIG. 10 is a sectional view showing a section of a coil of a reactor 2d according to a fourth modification example.
  • the section of FIG. 10 corresponds to the section of FIG. 6 . That is, FIG. 10 shows a sectional shape of portions of the wire 404 obtained by cutting those regions of the portions of the wire 404 which are in contact with the insulating heat radiation layer 12 along a plane containing an axis of the coil.
  • the portions of the wire 404 have exposed surfaces 404a that have slits 405 respectively.
  • the slits 405 are provided toward the inner side of the coil from the exposed surfaces 404a of the coil 5 respectively.
  • the slits 405 extend in an extending direction of the respective portions of the wire 404 of the coil 5.
  • Each of the slits 405 prevents each of the portions of the wire 404 from approaching the portions of the wire 404 that are adjacent thereto, due to thermal expansion.
  • Conductors are exposed from the exposed surfaces 404a respectively.
  • the slits 405 contribute towards preventing the exposed surfaces 404a that are adjacent to each other from short-circuiting to each other.
  • a plurality of short slits that are inclined with respect to the extending direction of the wire may be provided.
  • FIG. 11 is a sectional view showing a section of a coil of a reactor 2e according to a fifth modification example.
  • the section of FIG. 11 corresponds to a section obtained by further enlarging the section of FIG. 6 . That is, FIG. 11 shows a sectional shape of portions of the wire 504 obtained by cutting those regions of the portions of the wire 504 which are in contact with the insulating heat radiation layer 12 along a plane containing an axis of the coil.
  • spaces between the portions of the wire that are adjacent to each other in the pitch direction are filled with an insulating material 506, in those regions of the portions of the wire 504 which are in contact with the insulating heat radiation layer 12.
  • FIG. 12 is a sectional view showing a section of a coil of a reactor 2f according to a sixth modification example.
  • the sectional view of FIG. 12 corresponds to the sectional view of FIG. 11 .
  • the insulating heat radiation layer 12 includes two layers (an insulating ceramic board 121 and a silicon sheet 122).
  • the insulating ceramic board 121 is arranged on the side of the exposed surfaces 504a of the portions of the wire 504, and the silicon sheet 122 is arranged on the side of the cooler 6.
  • the insulating ceramic board 121 is in contact with the coil 5 (the exposed surfaces 504a of the portions of the wire 504).
  • the cooler 6 is made of conductive aluminum. When there are small air bubbles (microvoids) between the conductive cooler 6 and the coil 5, corona discharge may occur. Corona discharge causes carbonization of resin and the insulating film. The carbonized resin and the carbonized insulating film exhibit conductivity, so the exposed surfaces 504a that are adjacent to each other in the pitch direction may short-circuit to each other.
  • the insulating heat radiation layer 12 includes the insulating ceramic board 121 that is in contact with the coil 5, so carbonization does not occur near the exposed surfaces 504a that are adjacent to each other, which leads to the enhancement of reliability. Besides, a material with high thermal conductivity is selected for the insulating ceramic board 121. By adopting this insulating ceramic board 121, the effect of enhancing the efficiency of heat transmission from the coil 5 to the cooler 6 can also be expected.
  • the insulating ceramic board 121 is in direct contact with the exposed surfaces 504a of the portions of the wire 504.
  • the insulating ceramic board 121 may be embedded in the silicon sheet 122. That is, the insulating ceramic board 121 is not required to be in contact with the exposed surfaces 504a.
  • the rectangular wire 4 is wound into the shape of a prism having four flat lateral surfaces (the upper surface 5a, the lower surface 5d, the right lateral surface 5b, and the left lateral surface 5c) to create the coil 5.
  • the rectangular wire 4 is wound in an edgewise manner.
  • the wire 4 is covered with an insulating film along an entire circumference thereof. Part of the insulating film is removed later. That is, in a winding process, the wire 4 from which the insulating film has not been removed is wound into the coil 5 having at least one flat lateral surface.
  • the completed coil 5 is inserted through the core 20 ( FIG. 13 ).
  • the core 20 is divided into a plurality of core blocks. After the coil 5 is inserted through the columnar core block at a center, the core blocks in the other regions are joined thereto, and the core 20 is thus completed.
  • the resin cover 3 that covers the core 20 and the coil 5 is manufactured through mold forming ( FIG. 14 ). At this time, the lower surface of the core 20 and the lower surface 5d of the coil 5 are exposed. The insulating heat radiation layers 12 and 13 are attached to exposed regions of the core 20 and the coil 5, and the cooler 6 is further attached thereto.
  • the hard insulating material 506 is applied onto the exposed lower surface 5d of the coil 5. After the insulating material 506 has hardened, the lower surface 5d is polished ( FIG. 15 ). Each space between the portions of the wire 4 that are adjacent to each other in the pitch direction is filled with the insulating material 506, on the lower surface 5d of the coil 5.
  • the insulating material 506 is harder than the insulating film covering the wire 4.
  • the process of applying the insulating material 506 is a process required for the foregoing fifth modification example, and is not an absolutely indispensable process.
  • the lower surface 5d is polished to remove the insulating film, so that the degree of flatness of the lower surface 5d becomes lower than the degrees of flatness of the other lateral surfaces (the upper surface 5a, the right lateral surface 5b, and the left lateral surface 5c).
  • the lateral surfaces other than the lower surface 5d are not restrained, and the degrees of flatness thereof are allowed to be high.
  • the stress applied to the various spots of the coil 5 is alleviated.
  • the insulating material 506 fills up the spaces among the portions of the wire such that no polishing waste remains among the portions of the wire. Besides, as shown in FIG. 15 , the insulating material 506 also covers the corner portion that is adjacent to the lower surface 5d of the coil 5.
  • the insulating film 41 that covers the wire 4 is soft, and may adhere to a polishing surface of a grinder 30 when the grinder 30 separates from the coil 5.
  • a thick arrow in FIG. 15 indicates a moving direction of the grinder 30. In FIG. 15 , the grinder 30 that has polished the lower surface 5d separates from the lower-right corner portion of the coil 5.
  • the insulating film 41 can be prevented from adhering to the polishing surface of the grinder 30.
  • the insulating heat radiation layer 12 is stuck onto the lower surface 5d of the coil 5 from which the insulating film has been removed, the insulating heat radiation layer 13 is stuck onto the lower surface of the core 20, and the cooler 6 is attached to the opposite side of the insulating heat radiation layer.
  • the insulating heat radiation layers 12 and 13 are liquid in their initial states, and are applied to the lower surface 5d of the coil 5 and the lower surface of the core 20 respectively.
  • the cooler is attached before the liquid insulating heat radiation layers 12 and 13 are hardened.
  • the insulating heat radiation layer 12 (13) serves as an adhesive for bringing the coil 5 (the core 20) into close contact with the cooler 6.
  • the lower surface 5d of the coil which assumes the shape of a quadrangular prism, is opposed to the cooler 6, and the other lateral surfaces (the upper surface 5a, the right lateral surface 5b, and the left lateral surface 5c) are not opposed to the cooler 6.
  • the lower surface 5d that is opposed to the cooler 6 is an example of the first lateral surface
  • each of the other lateral surfaces is an example of the second lateral surface.
  • the coil may have two or more flat lateral surfaces that are opposed to the cooler via the insulating heat radiation layer.
  • the insulating heat radiation layer is stuck onto each of the flat lateral surfaces.
  • Each of the plurality of the flat lateral surfaces that are opposed to the cooler is an example of the first lateral surface
  • the lateral surface that is not opposed to the cooler is an example of the second lateral surface. Even in this case, the degree of flatness of each of the plurality of the first lateral surfaces is lower than the degree of flatness of the second lateral surface that is not opposed to the cooler.
  • the coil according to the embodiment has four flat lateral surfaces.
  • the reactor may have two or more flat lateral surfaces, or may have only one flat lateral surface.
  • the coil of the reactor may have a flat lateral surface, and a curved surface that is connected to both ends of the flat lateral surface.
  • a metal filler may be mixed into the insulating heat radiation layer 12 to enhance the efficiency of heat transmission.
  • the metal filler makes it easy to produce cracks (air bubbles).
  • the art according to the embodiment that can make the insulating heat radiation layer 12 thin is especially effective for the reactor that is equipped with the insulating heat radiation layer 12 into which the metal filler has been mixed.
  • the insulating heat radiation layer 12 is stuck onto the cooler 6 while being deployed from its rolled state, so as not to induce air between the insulating heat radiation layer 12 and the cooler 6.
  • the insulating heat radiation layer 12 is thick, the bending rigidity thereof is high.
  • a fissure is likely to be created therein.
  • the art described in the embodiment can make the thickness of the insulating heat radiation layer small. Consequently, even when the insulating heat radiation layer is rolled, a fissure is unlikely to be created therein.
  • the insulating film is removed through polishing, and at the same time, the degree of flatness of the first lateral surface of the coil is enhanced.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Transformer Cooling (AREA)
  • Insulating Of Coils (AREA)
EP19199511.7A 2018-09-25 2019-09-25 Reactor and method of manufacturing the same Active EP3633699B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2018179391 2018-09-25
JP2019018163A JP7081519B2 (ja) 2018-09-25 2019-02-04 リアクトルとその製造方法

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EP3633699A1 EP3633699A1 (en) 2020-04-08
EP3633699B1 true EP3633699B1 (en) 2022-04-13

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EP4170687A1 (en) * 2021-10-21 2023-04-26 Delta Electronics (Thailand) Public Co., Ltd. Electronic apparatus and manufacturing method for an electronic device

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JP2008186709A (ja) * 2007-01-30 2008-08-14 Mitsubishi Cable Ind Ltd 絶縁電線
JP2010118610A (ja) * 2008-11-14 2010-05-27 Sumitomo Electric Ind Ltd リアクトル
JP5597106B2 (ja) * 2010-11-19 2014-10-01 住友電気工業株式会社 リアクトル
JP5556692B2 (ja) * 2011-02-15 2014-07-23 トヨタ自動車株式会社 リアクトル
JP5692203B2 (ja) * 2012-11-12 2015-04-01 トヨタ自動車株式会社 リアクトルとその製造方法、及び、リアクトルを備えた電力変換装置とその製造方法
JP2016018797A (ja) * 2014-07-04 2016-02-01 株式会社豊田自動織機 誘導装置および誘導装置の製造方法
JP2016066686A (ja) * 2014-09-24 2016-04-28 株式会社オートネットワーク技術研究所 リアクトル
JP2016092313A (ja) * 2014-11-10 2016-05-23 三菱電機株式会社 磁気部品
JP2017041531A (ja) * 2015-08-19 2017-02-23 トヨタ自動車株式会社 平角線とコイル、およびコイルの製造方法
JP2017050334A (ja) * 2015-08-31 2017-03-09 トヨタ自動車株式会社 リアクトル
JP7189655B2 (ja) * 2016-09-16 2022-12-14 株式会社タムラ製作所 コイルおよびリアクトル
JP2018082129A (ja) * 2016-11-18 2018-05-24 トヨタ自動車株式会社 リアクトル

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KR102264347B1 (ko) 2021-06-11
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JP2020053666A (ja) 2020-04-02
EP3633699A1 (en) 2020-04-08

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