WO2011089941A1 - リアクトル - Google Patents
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- WO2011089941A1 WO2011089941A1 PCT/JP2011/050230 JP2011050230W WO2011089941A1 WO 2011089941 A1 WO2011089941 A1 WO 2011089941A1 JP 2011050230 W JP2011050230 W JP 2011050230W WO 2011089941 A1 WO2011089941 A1 WO 2011089941A1
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- coil
- reactor
- core portion
- case
- inner core
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- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
- B60L53/12—Inductive energy transfer
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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
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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
- H01F27/025—Constructional details relating to cooling
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/12—Electric charging stations
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/14—Plug-in electric vehicles
Definitions
- the present invention relates to a reactor used for a component part of a power conversion device such as an in-vehicle DC-DC converter.
- converters that perform step-up and step-down operations are required to drive the driving motor and charge the battery. Even in a fuel cell vehicle, the output of the fuel cell is boosted.
- One of the converter components is a reactor.
- the reactor include a form in which a pair of coils formed by winding a winding around the outer periphery of an O-shaped magnetic core are arranged in parallel.
- Patent document 1 arrange
- a reactor including a so-called pot-type core having an E-shaped cross-section having a pair of disk-shaped connecting core portions is disclosed.
- the inner core portion and the outer core portion arranged concentrically are connected by the connecting core portion to form a closed magnetic circuit.
- the inner core portion and the coil are covered with the outer core portion and the connecting core portion.
- heat generated in the reactor due to copper loss and iron loss is difficult to dissipate.
- a current of about several hundred amperes may flow through the reactor, the heat generated by the coil is large, and the internal temperature of the reactor may rise to a high temperature of 100 ° C. or higher.
- the present invention provides a reactor that can effectively dissipate heat generated inside the reactor even when the outside of the coil is covered with a core material.
- a reactor provided by the present invention includes a coil, a core having an inner core portion disposed inside the coil, an outer core portion covering the outside of the coil, and a case for housing the coil and the core. It is a reactor, Comprising: The said case has the thermal radiation structure with respect to at least one of the said coil and the said inner core part in an inner wall surface, and the said outer core part has a shape according to the said thermal radiation structure.
- a heat dissipation structure for at least one of the coil and the inner core portion is provided on the inner wall surface of the case. For this reason, even when the outer side of a coil is covered with the core material, the heat dissipation of at least one of a coil and an inner core part can be improved by the heat dissipation structure in a case.
- the heat dissipating structure can include a heat transfer portion that projects a part of the inner wall surface of the case. By protruding a part of the inner wall surface of the case, the inner wall surface can be brought closer to at least one of the coil and the inner core portion. Therefore, the heat dissipation of at least one of the coil and the inner core portion is improved.
- the heat dissipation structure is not similar to the outer wall surface of the case, and may be configured by an inner wall surface formed in accordance with the outer shape of at least one of the coil and the inner core portion.
- an inner wall surface formed in accordance with the outer shape of at least one of the coil and the inner core portion.
- At least the outer core portion of the core is formed of a mixture of a magnetic material and a resin.
- the coil is arranged with its axial direction substantially parallel to the bottom surface of the case. Thereby, heat can be easily dissipated to the bottom surface of the cooled case.
- the heat dissipation of at least one of the coil and the inner core part can be improved.
- FIG. 1 is a diagram showing an installation state of a reactor according to an embodiment of the present invention.
- FIG. 2 is a perspective view showing a schematic configuration of the reactor according to the present embodiment.
- FIG. 3 is a cross-sectional view of the reactor for explaining the configuration of the heat transfer section.
- FIG. 4 is a cross-sectional view illustrating a reactor having a fin-shaped heat transfer portion on the inner surface of a side wall as a heat transfer portion according to another example.
- FIG. 1 is a diagram showing an installation state of a reactor according to an embodiment of the present invention.
- FIG. 2 is a perspective view showing a schematic configuration of the reactor according to the present embodiment.
- FIG. 3 is a cross-sectional view of the reactor for explaining the configuration of the heat transfer section.
- FIG. 4 is a cross-sectional view illustrating a reactor having a fin-shaped heat transfer portion on the inner surface of a side wall as a heat transfer portion according to another example.
- FIG. 1 is a diagram showing
- FIG. 5A is a diagram for explaining a reactor having rectangular plate-shaped heat transfer portions at the four corners inside the case as a heat transfer portion according to another example, in the case where the reactor is cut just inside the side wall 212 along the side wall 212. It is a side view.
- Drawing 5B is a figure explaining a reactor which has a rectangular-plate-like heat-transfer part in a case inside four corners as a heat-transfer part concerning other examples, and is a top view at the time of cutting a reactor in the end face direction of a coil. is there.
- FIG. 6 is a diagram for explaining a reactor having a heat transfer portion in which a plurality of plate-like portions are arranged radially as a heat transfer portion according to still another example.
- FIG. 7A is a view for explaining a reactor having a spiral heat transfer section as a heat transfer section according to still another example, and is a side view when the reactor is cut just inside the side wall 212.
- Drawing 7B is a figure explaining a reactor which has a spiral heat-transfer part as a heat transfer part concerning other examples, and is a top view at the time of cutting a reactor in the end face direction of a coil.
- FIG. 8A is a diagram illustrating a configuration of a reactor having a case in which an inner wall surface is formed in accordance with the outer shape of a coil and an inner core portion as a heat dissipation structure of a case according to another example. It is a side view at the time of cut
- FIG. 8B is a diagram for explaining a configuration of a reactor having a case in which an inner wall surface is formed in accordance with the outer shape of the coil and the inner core portion as a heat dissipation structure of the case according to another example, and the reactor is cut in the end face direction of the coil.
- FIG. 9A shows a configuration of a reactor having a case in which a heat transfer portion is formed in conformity with an outer shape of a coil and an inner core portion that are arranged substantially parallel to the bottom surface of the case as a heat dissipation structure of the case according to another example. It is a figure explaining and is a side view at the time of cut
- FIG. 9B shows a configuration of a reactor having a case in which a heat transfer portion is formed in conformity with the outer shape of a coil and an inner core portion that are arranged substantially parallel to the bottom surface of the case as a heat dissipation structure of the case according to another example. It is a figure explaining and is a top view when it sees from upper direction.
- FIG. 10A is a diagram for explaining a configuration of a reactor having a case in which inner wall surfaces are formed in accordance with the outer shapes of a plurality of coil elements as a heat dissipation structure for a case according to another example. It is a side view at the time of cut
- FIG. 10B is a diagram for explaining a configuration of a reactor having a case in which inner wall surfaces are formed in accordance with the outer shapes of a plurality of coil elements as a heat dissipation structure for a case according to another example. It is a top view at the time of cut
- FIG. 11 is a diagram illustrating a configuration of a reactor including a case having a heat dissipation structure on the outer wall and a lid.
- FIG. 1 is a diagram showing an installation state of a reactor according to an embodiment of the present invention.
- Reactor 101 according to the present embodiment can be used as a component of an in-vehicle DC-DC converter.
- Reactor 101 is housed in an aluminum converter case 102 together with other components.
- the reactor 101 includes a case 103 made of aluminum, for example, a box-lid shape, and is disposed in the converter case 102 by fixing the case 103 to the inner bottom surface 104 of the converter case 102 with a bolt. Yes.
- the bottom surface of the case 103 is in surface contact with the inner bottom surface 104 of the converter case 102.
- a current of several hundred amperes may be passed through the reactor 101, and the reactor 101 generates high heat.
- cooling water 105 is introduced into the outer bottom surface of the converter case 102. Heat generated by the reactor 101 is transmitted to the converter case 102 through the bottom surface of the case 103 and is dissipated by the cooling water 105.
- FIG. 2 is a perspective view showing a schematic configuration of the reactor according to the present embodiment.
- the reactor 101 includes a coil 201, a core 204 having an inner core portion 202 disposed inside the coil 201, and an outer core portion 203 covering the outside of the coil 201.
- a case 103 provided in the reactor 101 accommodates the coil 201 and the core 204.
- the coil 201 is formed by spirally winding one continuous winding 201w, and the axial direction 205 thereof is arranged in parallel with the normal direction of the bottom surface of the case 103. Both ends of the winding 201w are connected to a semiconductor element of the converter and a battery.
- the winding 201w it is preferable to use a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor made of a conductive material such as copper or aluminum.
- a covered rectangular wire whose conductor is made of a copper rectangular wire and whose insulating coating is made of enamel is used for the winding 201w.
- various shapes such as a circular shape and a polygonal shape can be used.
- the reactor having the above-described configuration is used in applications where the energization conditions are, for example, a maximum current (DC) of about 100 A to 1000 A, an average voltage of about 100 V to 1000 V, and a usage frequency of about 5 kHz to 100 kHz, typically an electric vehicle or It can utilize suitably for the components of in-vehicle power converters, such as a hybrid car. In such applications, it is expected that an inductance satisfying 10 ⁇ H or more and 2 mH or less when DC current is 0 A and 10% or more of inductance when DC current is 0 A is preferably used. If the reactor and vehicle parts, reactor is preferably capacitance, including the case is 0.2 liters (200cm 3) ⁇ 0.8 liters (800 cm 3) approximately.
- the coil 201 forms one coil element, but a plurality of coil elements may be formed by one winding, and these coil elements may be accommodated in a case.
- the plurality of coil elements can be formed by separate windings instead of a single winding.
- welding of separate windings include TIG welding, laser welding, and resistance welding.
- the ends of the windings may be joined to each other by crimping, cold welding, vibration welding, or the like.
- Both ends of the winding 201w forming the coil 201 are appropriately extended from the turn and drawn to the outside of the outer core portion 203, and the conductive portion such as copper or aluminum is exposed to the exposed conductor portion by peeling off the insulation coating.
- a terminal member made of a conductive material is connected.
- the coil 201 is connected to a battery or the like through this terminal member.
- welding such as TIG welding, crimping or the like can be used to connect both ends of the winding 201w and the terminal member.
- the core 204 forms a closed magnetic circuit by integrating the inner core portion 202 and the outer core portion 203.
- the constituent material is different between the inner core portion 202 and the outer core portion 203, and the magnetic characteristics are different.
- the inner core portion 202 has a higher saturation magnetic flux density than the outer core portion 203
- the outer core portion 203 has a lower magnetic permeability than the inner core portion 202.
- the inner core part 202 has an outer shape along the shape of the inner peripheral surface of the coil 201 (or each coil element when a plurality of coil elements are formed). Here, it has a cylindrical outer shape. You may have the external shape like the rectangular parallelepiped (track shape) in which the end surface shape rounded the angle
- the inner core portion 202 is entirely composed of a green compact and can be configured such that no gap material, air gap, or adhesive is present. Alternatively, the inner core portion 202 can be constituted by a plurality of cores by interposing a gap material, an air gap, or an adhesive material.
- the green compact is typically obtained by molding a soft magnetic powder having an insulating coating on the surface and firing it at a temperature lower than the heat resistance temperature of the insulating coating.
- a mixed powder in which a binder is appropriately mixed in addition to the soft magnetic powder can be used, or a powder having a coating made of a silicone resin or the like can be used as an insulating coating.
- the saturation magnetic flux density of the green compact can be changed by adjusting the material of the soft magnetic powder, the mixing ratio of the soft magnetic powder and the binder, the amount of various coatings, and the like.
- a powder compact with a high saturation magnetic flux density can be obtained by using a soft magnetic powder with a high saturation magnetic flux density or by increasing the proportion of the soft magnetic material by reducing the blending amount of the binder.
- the saturation magnetic flux density tends to be increased by changing the molding pressure, specifically, by increasing the molding pressure. It is preferable to select a soft magnetic powder and adjust a molding pressure so as to obtain a desired saturation magnetic flux density.
- Soft magnetic powders include iron group metal powders such as Fe, Co, and Ni, Fe-based alloy powders such as Fe—Si, Fe—Ni, Fe—Al, Fe—Co, Fe—Cr, and Fe—Si—Al, Or rare earth metal powder, ferrite powder, etc. can be used.
- the Fe-based alloy powder is easy to obtain a green compact with a high saturation magnetic flux density.
- Such a powder can be produced by an atomizing method (gas or water), a mechanical pulverization method, or the like.
- a powder made of a nanocrystalline material having a nanosized crystal preferably a powder made of an anisotropic nanocrystalline material, a compact with a high anisotropy and a low coercive force is obtained.
- a phosphoric acid compound, a silicon compound, a zirconium compound, or a boron compound is used.
- a thermoplastic resin, a non-thermoplastic resin, a higher fatty acid, or the like can be used as the binder. This binder disappears upon firing, or changes to an insulator such as silica.
- an insulator such as an insulating coating allows soft magnetic powders to be insulated from each other, reducing eddy current loss, and applying high-frequency power to the coil. However, the loss can be reduced.
- the inner core portion 202 includes not only the entirety of the inner core portion 202 disposed in the coil (element) but also a portion of the inner core portion 202 protruding from the coil (element).
- the axial length of the coil 201 in the inner core portion 202 is larger than that of the coil 201, and both end portions of each inner core portion 202 protrude from the end surface of the coil 201.
- the length of the inner core portion 202 may be equal to the coil 201 or may be slightly shorter. When the length of the inner core portion 202 is equal to or greater than that of each coil 201, the magnetic flux generated by the coil 201 can be sufficiently passed through the inner core portion 202.
- the outer core part 203 is formed so as to cover substantially all of the coil 201 and the inner core part 202 in the present embodiment. That is, the outer core portion 203 substantially covers the entire outer periphery of the coil 201, both end surfaces of the coil 201, and both end surfaces of the inner core portion 202.
- the inner core portion 202 and the outer core portion 203 are joined by the constituent resin of the outer core portion 203 without an adhesive. By the joining, the core 204 can be integrated without a gap throughout the core 204.
- the outer core portion 203 has a rectangular parallelepiped outer shape that matches the inner wall surface of the case as a basic outer shape, but the shape of the outer core portion 203 is not particularly limited as long as a closed magnetic circuit can be formed. A part of the outer side of the coil 201 may be exposed without being covered with the outer core part 203.
- the entire outer core portion 203 can be formed of a mixture (molded and cured body) of a magnetic material and a resin.
- the molded cured body can typically be formed by injection molding or cast molding. Injection molding usually involves mixing soft magnetic powder (mixed powder with non-magnetic powder added if necessary) and fluid binder resin, and applying this mixed fluid to a mold by applying a predetermined pressure. After casting and molding, the binder resin is cured. In cast molding, a mixed fluid similar to that of injection molding is obtained, and then the mixed fluid is injected into a molding die without applying pressure to be molded and cured. In any molding technique, a thermosetting resin such as an epoxy resin, a phenol resin, or a silicone resin can be suitably used as the binder resin.
- a thermosetting resin such as an epoxy resin, a phenol resin, or a silicone resin can be suitably used as the binder resin.
- thermosetting resin When a thermosetting resin is used as the binder resin, the molded body is heated to thermoset the resin.
- a normal temperature curable resin or a low temperature curable resin may be used as the binder resin.
- the molded body is allowed to stand at a normal temperature to a relatively low temperature to be cured. Since the molded hardened body contains a large amount of binder resin, which is a non-magnetic material, even if the same soft magnetic powder as that of the green compact is used, the saturation magnetic flux density is lower and the permeability is lower than that of the green compact. Become.
- the soft magnetic powder and non-magnetic powder can be mixed with soft magnetic powder (or non-magnetic powder) and binder resin.
- the magnetic permeability of the outer core portion can be adjusted. For example, when the blending amount of the soft magnetic powder is reduced, the magnetic permeability tends to decrease.
- the magnetic permeability of the outer core portion 203 may be adjusted so that the reactor 101 has a desired inductance.
- the soft magnetic powder used for the outer core portion 203 the same soft magnetic powder as used for the inner core portion 202 described above can be used. It is preferable to interpose an insulator at a location where the core 204 is in contact with the coil 201 in order to further improve the insulation between them.
- an insulating tape is attached to the inner and outer peripheral surfaces of the coil 201, or insulating paper or an insulating sheet is disposed.
- a bobbin made of an insulating material may be disposed on the outer periphery of the inner core portion 202.
- an insulating resin such as polyphenylene sulfide (PPS) resin, liquid crystal polymer (LCP), polytetrafluoroethylene (PTFE) resin can be suitably used.
- the saturation magnetic flux density of the inner core portion 202 is higher than that of the outer core portion 203, so that the total magnetic flux passing through the inner core portion 202 is uniform with the same saturated core.
- the cross-sectional area (surface through which the magnetic flux passes) of the inner core portion 202 may be made smaller than the cross-sectional area of the inner core of the uniform core. it can.
- the reactor 101 can have a desired inductance because the saturation magnetic flux density of the inner core portion 202 is high and the magnetic permeability of the outer core portion 203 is low. Furthermore, in the reactor 101, when there is no gap including an adhesive throughout the core 204, the leakage magnetic flux at the gap does not affect the coil 201. The inner peripheral surface of the can be placed close to each other. Therefore, the gap between the outer peripheral surface of the inner core portion 202 and the inner peripheral surface of the coil 201 can be reduced, and from this, the reactor 101 can be downsized.
- the gap material joining step and the like are not required when forming the inner core portion 202, and thus the productivity is excellent.
- the inner core portion 202 and the outer core portion 203 are joined by the constituent resin of the outer core portion 203 to form the core 204.
- the reactor 101 is manufactured. Therefore, the manufacturing process is simplified, and productivity is improved from this point.
- the reactor 101 has an adhesive-less structure, inductance mismatch due to variations in adhesive thickness is unlikely to occur. Further, in the reactor 101, the saturation magnetic flux density can be easily adjusted by forming the inner core portion 202 as a compact, and even a complicated three-dimensional shape can be easily formed.
- the outer core portion 203 includes a resin component, protection from the external environment such as dust and corrosion and mechanical protection can be achieved. In particular, in the reactor 101, the entire coil 201 is covered with the outer core portion 203, whereby the outer core portion 203 can be easily formed and the coil 201 can be sufficiently protected. Thus, the reactor 101 has various advantages.
- the reactor 101 covers the whole coil 201 with the outer core part 203, it is easy to suppress the internal temperature. As described with reference to FIG. 1, the reactor 101 cools its bottom surface, and therefore, the bottom surface side is relatively easy to reduce the internal temperature.
- the upper surface side of the reactor 101 is farthest from the bottom surface of the case 103 and is not covered by the case like the bottom surface or side surface of the reactor 101.
- the heat dissipation is performed mainly through a route from the inner core portion 202 to the bottom surface and a route from the outer core portion 203 and the side wall of the case to the bottom surface, and the temperature is relatively likely to rise.
- the outer core portion 203 is formed of a mixture of a magnetic material and a resin, the thermal conductivity is lower than that of the inner core portion 202, and this tendency is increased.
- the reactor 101 includes the case 103 having the heat transfer portion 206 on the inner wall surface 207 as a heat dissipation structure for at least one of the coil 201 and the inner core portion 202.
- the heat transfer unit 206 is a part of the inner wall surface 207 of the case 103 that protrudes, and constitutes part or all of the inner wall surface 207 that is not similar to the outer wall surface 208.
- the outer core portion 203 is formed according to the shape of the heat transfer portion 206, and the inner wall surface 207 is similar to the outer wall surface 208 than in the case of the coil 201 and the inner core portion 202. At least one is closer to the inner wall surface 207. Therefore, the heat dissipation of at least one of the coil 201 and the inner core portion 202 is enhanced.
- the heat transfer section 206 is provided on the side walls 209 and 210 of the side walls 209 to 212 of the case 103, and constitutes a part of the inner wall surface of these side walls.
- the base shape of the inner wall surface 207 is a rectangular parallelepiped shape similar to the outer wall surface 208.
- the inner wall surface 207 is not similar to the outer wall surface 208 by providing the heat transfer portion 206 protruding from the base surface toward the coil 201 and the inner core portion 202. Due to the protrusion, the inner wall surface 207 (the heat transfer portion 206 thereof) comes into contact with the coil 201 and the inner core portion 202.
- the heat transfer unit 206 includes not only a part integrally formed as a part of the case 103 but also a part formed separately from the same or different material as the case 103 main body and fixed to the main body.
- a material for the heat transfer section 206 other metal materials such as aluminum alloy, and ceramics such as silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide can be used in addition to aluminum. Since the heat transfer part 206 having high thermal conductivity comes into contact with (or close to) the coil 201 and the inner core part 202 without (almost) the outer core part 203 or the like, the heat inside the reactor 101 is effectively dissipated. . In addition, when using the heat-transfer part 206 also as a rib, it is necessary to select the raw material of the heat-transfer part 206 also considering mechanical strength.
- the coil 201 and the inner core portion 202 made of a green compact are prepared, and the inner core portion 202 is inserted into the coil 201.
- an insulator may be appropriately disposed between the coil 201 and the inner core portion 202.
- the assembly of the coil 201 and the inner core portion 202 is accommodated in the case 103 in which the heat transfer portion 206 is formed.
- a mixed fluid of a magnetic material and a binder resin constituting the outer core portion 203 is appropriately poured into the case 103.
- the outer core portion 203 is formed by filling the mixture of the magnetic material and the resin, even if the inner wall surface 207 of the case 103 has a complicated shape due to the heat dissipation structure, it corresponds to the heat dissipation structure.
- the outer core portion 203 can be configured, and the reactor 101 can be manufactured relatively easily.
- the heat transfer section 206 is not provided on the side walls 211 and 212 of the case 103. Therefore, in the vicinity of the side walls 211 and 212, the outer core portion 203 is formed to communicate with the axial direction of the coil 201 so as to connect the other end of the inner core portion 202 to the other end. In this portion, a large annular (closed) magnetic path of the inner side ⁇ outer side ⁇ inside of the coil 201 is secured along the inner core portion 202 and the outer core portion 203. As a result, desired magnetic characteristics can be obtained even if the heat transfer section 206 is provided on the inner wall surface 207 of the case 103.
- the inner wall on which the heat transfer section 206 is provided is not limited to this example, and can be determined as appropriate within a range in which a magnetic path can be secured in this way.
- the heat transfer section 206 is formed on the inside of the case 103 so as to come into contact with the protruding portion 206A protruding from the inner wall surface 207 of the case 103 so as to contact the outer peripheral surface of the coil 201 and the inner core portion 202 protruding from the end face of the coil 201. And a protruding portion 206B protruding from the wall surface 207.
- the protruding portion 206A has a concave surface that matches the outer peripheral surface of the coil 201 as a contact surface
- the protruding portion 206B has a concave surface that matches the outer peripheral surface of the inner core portion 202 as a contact surface. Due to this concave surface, the contact (or proximity) area becomes larger than in the case of a flat surface, and heat is easily dissipated from the coil 201 and the inner core portion 202 by that amount.
- FIG. 3 is a cross-sectional view of the reactor for explaining the configuration of the heat transfer section.
- the protrusion 206 ⁇ / b> A is continuous with the protrusion 206 ⁇ / b> B and the axial direction 205 of the coil 201.
- the protrusion 206 ⁇ / b> B is provided on the side walls 209 and 210 of the case 103 and is continuous with the bottom surface 301 of the case 103. Heat from the coil 201 is transmitted to the bottom surface 301 of the case 103 through the protrusions 206A and 206B. For this reason, it becomes easier to dissipate heat from the coil 201 than when only the protrusion 206A is provided.
- the protruding portion 206 ⁇ / b> B continuously with the bottom surface 301 of the case 103, heat from the inner core portion 202 is easily transmitted to the bottom surface 301.
- the protrusion 206 ⁇ / b> B also contacts a part of the lower end surface of the coil 201 at the upper end surface. Therefore, the protrusion 206 ⁇ / b> B can contribute to cooling of the coil 201.
- the lower end portion 302 of the inner core portion 202 is in surface contact with the bottom surface 301 of the case 103.
- the inner core portion 202 has a higher thermal conductivity than the outer core portion 203.
- the heat transfer part 206 has the protrusions 206A and 206B, it may have only one of them. Furthermore, you may make it provide the heat-transfer part (or protrusion part) like the protrusion part 206B in the upper end side of the coil 201.
- FIG. The upper surface side of the reactor 101 is not covered with the case 103, and in particular, the center portion is separated from the side walls 209 to 212 of the case 103, and therefore, the temperature tends to increase. By providing the heat transfer section on the upper end side of the coil 201, it is possible to effectively dissipate heat on the upper surface side of the reactor 101.
- the protrusions 206A and 206B are close to the coil 201 and the inner core part 202 by a concave surface, but may be close to the coil 201 and the inner core part 202 by a flat surface or a convex surface. Since the coil 201 is cylindrical and the inner core portion 202 is columnar, and the inner wall surface of the case 103 has a rectangular parallelepiped shape, when it is flat or convex, a part of the heat transfer portion is more coiled or inner than the other portion. It will be close to the core part 202. However, since the proximity portion protrudes from the base surface of the inner wall, heat can be easily dissipated from the coil 201 or the inner core portion 202 by that amount.
- FIG. 4 is a cross-sectional view illustrating a reactor having a fin-like heat transfer portion on the inner surface of a side wall as a heat transfer portion according to another example.
- the heat transfer unit 401 is provided on the side walls 209 and 210 of the case 103 as in the example of FIG.
- the heat transfer section 401 has a plurality of fin-like protrusions. For example, a plurality of triangular plate pieces arranged on the side wall 209 or 210 parallel to the bottom surface 301 of the case 103 and the axial direction 205 of the coil 201 are arranged. Composed by arranging.
- the heat transfer unit 401 is not in contact with the coil 201 or the inner core unit 202, but may be in contact.
- the outer core portion 203 is also formed in that portion, and a magnetic path is secured.
- the heat transfer portion 401 is not in contact with the coil 201 or the inner core portion 202, the inner wall surfaces of the side walls 209 and 210 are closer to the coil 201 and the inner core portion 202 than the base surface due to the presence of the heat transfer portion 401. To do. For this reason, it becomes easy to dissipate heat from the coil 201 and the inner core portion 202 to the case 103. Moreover, by providing the heat transfer part 401, the surface areas of the inner wall surfaces of the side walls 209 and 210 are increased, and it is easy to radiate heat.
- FIG. 5A and FIG. 5B are diagrams illustrating a reactor having rectangular plate-shaped heat transfer portions at four corners inside the case as heat transfer portions according to still another example.
- FIG. 5A is a side view when the reactor is cut along the side wall 212 right inside thereof
- FIG. 5B is a plan view when the reactor is cut in the end face direction of the coil.
- the heat transfer section 501 is provided at locations corresponding to the inner four corners of the box-shaped case 103.
- the distance between the coil 201 and the side walls 209 to 212 of the case 103 is particularly large at the four corners.
- Each of the heat transfer portions 501 has a shape like a rectangular plate with a corner portion that is in contact with the inner core portion 202 missing, and is provided in a form in which the rectangular plate is placed on the bottom surface 301 of the case 103. ing.
- the heat transfer unit 501 may have a rectangular plate or other shapes.
- the upper surface of the heat transfer section 501 is also in contact with a part of the lower end surface of the coil 201, and can contribute to dissipating the heat of the coil 201.
- the upper surface of the heat transfer unit 501 may be separated from the lower end surface of the coil 201, and even in that case, the heat transfer unit 501 comes close to the lower end surface of the coil 201, so that the heat from the coil 201 is dissipated. easy. Furthermore, since the heat transfer unit 501 is continuous with the bottom surface 301 of the case 103, heat is easily transferred from the coil 201 and the inner core unit 202 to the bottom surface 301.
- a heat transfer unit similar to the heat transfer unit 501 may be provided on the upper surface side of the reactor 1 instead of or in addition to the heat transfer unit 501. Furthermore, a columnar heat transfer section having the same cross-sectional shape as the heat transfer section 501 and extending in the axial direction 205 of the coil 201 can be provided. In this case, it is possible to efficiently improve the heat dissipation performance of the portion far from the side wall of the case 103.
- the mixture of the magnetic material and the resin constituting the outer core portion 203 is filled between the heat transfer portions, and a magnetic path is secured in the outer core portion 203.
- FIG. 6 is a diagram for explaining a reactor having a heat transfer portion in which a plurality of plate-like portions are arranged radially as a heat transfer portion according to still another example.
- the heat transfer part 601 is configured by arranging a plurality of plate-like parts standing on the bottom surface 301 of the case 103 along the axial direction of the coil 201 in a radial pattern with the inner core part 202 as the center.
- the thickness of the plate-like portion provided at the inner four corners is larger than the plate-like portion at the center of each side wall.
- the thickness of each plate-like portion may be the same, and the number of plate-like portions is not limited to this example.
- each heat transfer unit 601 is in contact with the coil 201.
- heat on the outer peripheral surface of the coil 201 can be easily dissipated to the side walls 209 to 212 of the case 103, and thus to the bottom surface 301.
- the heat transfer unit 601 does not necessarily need to be in contact with the coil 201.
- the radial heat transfer part 601 may be close to or in contact with the coil 201 and the inner core part 202.
- the outer core portion 203 is formed between the plate-like portions, and a large magnetic path can be secured at that portion.
- FIG. 7A and FIG. 7B are diagrams illustrating a reactor having a spiral heat transfer portion as a heat transfer portion according to still another example.
- the heat transfer unit 701 is provided on the inner wall surfaces of the side walls 211 and 212 of the case 103.
- the two heat transfer units 701 are formed in a spiral shape around the coil 201.
- the heat transfer unit 701 also easily dissipates heat in contact with or close to the coil 201 (and the inner core unit 202).
- a gap is provided between the linear portions (for example, 701A and 701B) constituting the spiral. Since the outer core portion 203 is also formed in this gap, a magnetic path can be formed in that portion.
- the coil 201 can dissipate heat relatively uniformly and can contribute to the formation of a magnetic path.
- FIGS. 8A and 8B are diagrams illustrating a configuration of a reactor having a case in which an inner wall surface is formed according to the outer shape of a coil and an inner core portion as a heat dissipation structure of a case according to another example.
- the heat dissipation structure according to this example includes an inner wall surface 801 that is formed in a columnar shape in accordance with the outer shape of the coil 201 and the inner core portion 202. Since the outer shape of the case 103 is a rectangular parallelepiped, the outer wall surface 208 and the inner wall surface 801 are dissimilar. An imaginary line 802 virtually shows the inner wall surface when formed in a rectangular parallelepiped shape similar to the outer wall surface 208.
- the side wall of the case 103 is formed by forming the cylindrical inner wall surface 801 in accordance with the outer shape of the coil 201 and the inner core portion 202. It is closer to the inner core portion 202.
- the outer core portion 203 is formed in a cylindrical shape so as to fill a gap in accordance with the shape of the inner wall surface 801, and the outer core extends over the entire circumferential direction of the cylindrical coil 201.
- the thickness of the portion 203 is evenly suppressed. Therefore, heat can be easily and evenly dissipated from the coil 201 and the inner core portion 202 to the bottom surface 301 of the case 103.
- the outer core portion 203 is formed in a cylindrical shape, variations in the magnetic path length over the entire circumferential direction of the coil 201 can be suppressed. As a result, the designed magnetic characteristics can be obtained more easily. Furthermore, it contributes to reducing an extra core material about the outer core part 203.
- the shape of the coil 201 may be other shapes.
- FIGS. 9A and 9B are diagrams illustrating a configuration of a reactor in which a coil is disposed substantially parallel to the bottom surface of the case as a heat dissipation structure of the case according to another example.
- the heat dissipation structure according to this example includes a coil 201, an inner core portion 202, and a heat transfer portion 701.
- the outer core part 203 is formed so as to fill a gap according to its shape.
- the bottom surface of the case 103 comes closer to the coil 201 and the inner core portion 202, and the coil 201 and the inner core portion 202 pass through the heat transfer portion 701.
- heat can be easily dissipated to the bottom surface 301 of the case 103.
- the end surface shape of the coil 201 may be other shapes such as a rectangle, an ellipse, and a race track shape.
- FIG. 10A and FIG. 10B are diagrams illustrating the configuration of a reactor having a case in which inner wall surfaces are formed in accordance with the outer shapes of a plurality of coil elements as a heat dissipation structure of a case according to another example.
- the coil includes two coil elements 201A and 201B, and an inner core portion 202A or 202B is prepared for each coil element 201A or 201B.
- Each of the coil elements 201A and 201B has a rectangular shape (track shape) with rounded corners.
- the inner wall surface 901 of the case 103 is formed so that the cross-sectional shape becomes a track shape in accordance with an envelope connecting the outer shapes of the two coil elements 201A and 201B. Even at the rounded corner portion of the track shape, the outer peripheral surface of the coil element 201A or 201B and the inner wall surface 901 are parallel. Since the outer shape of the case 103 is a rectangular parallelepiped, the outer wall surface 208 and the inner wall surface 901 are not similar. By making the long side / short side ratio of the rectangle serving as the base of the track shape different from the rectangle of the cross section of the case 103, the outer wall surface 208 and the inner wall surface 901 can be made to be non-similar.
- An imaginary line 902 virtually shows the inner wall surface when formed in a rectangular parallelepiped shape similar to the outer wall surface 208.
- the inner wall surface 901 having a cross-sectional track shape is formed in accordance with the outer shape of the coil elements 201A and 201B.
- the side wall of the case 103 comes closer to the coil elements 201A and 201B. Therefore, heat can be easily dissipated from the coil elements 201A and 201B to the bottom surface 301 of the case 103.
- the inner wall surface 901 can be formed in accordance with an envelope connecting the outer shapes of the coil elements.
- an inner wall surface matched to the outer shape of each coil element may be formed.
- an inner wall surface matching the outer shape of each coil element 201A or 201B is formed.
- a section where the coil elements 201A and 201B are parallel to the inner wall surface is also provided in a portion sandwiched between the coil elements 201A and 201B.
- FIG. 11 is a diagram illustrating the configuration of a reactor including a case having a heat dissipation structure on the outer wall and a lid.
- the heat transfer unit 1001 is provided at locations corresponding to the inner four corners on the bottom surface 301 side of the case 103, as in the example of FIGS. 5A and 5B.
- the heat transfer unit 1001 is an example for explaining the configuration of FIG. 11, and is not limited to this.
- the outer wall 208 of the side wall of the case 103 also has a heat dissipation structure 1002.
- the heat dissipation structure 1002 has a structure in which a plurality of plate-like pieces arranged in parallel with the bottom surface of the case 103 are arranged on the outer wall surface 208 of the side wall of the case 103 in the axial direction of the coil 201.
- the heat dissipation structure of the outer wall surface 208 is not limited to this example, and may be configured by, for example, a plurality of needle-like protrusions arranged over the entire outer wall surface of the side wall.
- the heat dissipation structure 1002 also on the outer wall surface 208 of the case 103, the heat transferred from the coil 201 and the inner core portion 202 to the side wall of the case 103 is more effectively dissipated. Therefore, heat dissipation is improved as a whole reactor.
- the case 103 has a lid 1003 that closes the upper portion thereof.
- the case 103 has an open upper surface, and a part of the outer core portion 203 is exposed.
- the upper portion of the case 103 is closed with a lid 1003 made of, for example, aluminum, and the upper surface of the reactor is in surface contact with the lid 1003.
- the heat on the upper surface of the reactor is also dissipated in the path from the lid 1003 and the side wall of the case 103 to the bottom surface 301.
- lid 1003 and the case 103 are formed of a conductive material such as a metal material, the lid 1003 and the case 103 also function as an electromagnetic shield.
- the heat transfer section 1004 is also provided at locations corresponding to the four corners on the upper surface side of the case 103.
- the heat transfer unit 1004 contacts the side surface of the portion protruding from the coil 201 above the inner core unit 202 and also contacts a part of the upper end surface of the coil 201.
- the heat transfer unit 1004 also contacts the lid 1003 when the lid 1003 is closed. Therefore, heat can be more effectively dissipated from the coil 201 and the inner core portion 202 via the heat transfer portion 1004 and the lid 1003.
- the heat transfer unit 1004 may be provided on the lid 1003 side.
- the outer core portion 203 is formed into a shape that avoids the heat transfer portion of the lid 1003. Accordingly, heat can be effectively transferred from the coil 201 and the inner core portion 202 to the lid 1003.
- the reactor of the present invention can be applied not only to a vehicle-mounted converter but also to a power converter having a relatively high output, such as an air conditioner converter.
- the reactor accommodated in the case can also be manufactured by preparing a combination of a coil and a core, storing it in the case, and filling a potting resin prepared separately.
- Potting resins include epoxy resins, urethane resins, PPS resins, polybutylene terephthalate (PBT) resins, acrylonitrile-butadiene-styrene (ABS) resins, and silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide. What mixed the filler which consists of at least 1 sort (s) of selected ceramics etc. can be utilized. By containing a filler, the heat dissipation of a reactor can be improved. Furthermore, the present invention is not limited to a reactor housed in the case so that the axial direction of the coil is parallel to the normal direction of the bottom surface of the case. For example, the case where the axial direction of the coil is parallel to the bottom surface of the case. It is also possible to apply to a reactor housed in the reactor.
- this invention was demonstrated about the reactor by which an inner core part is comprised with a compacting body.
- stacked the electromagnetic steel plate represented by the silicon steel plate can also be utilized as an inner core part.
- the magnetic steel sheet is easy to obtain a magnetic core having a high saturation magnetic flux density as compared with the green compact.
- the inner core portion has a higher saturation magnetic flux density than the outer core portion, and the outer core portion has a lower magnetic permeability than the inner core portion, but the reactor to which the present invention is applied is It is not limited to the example.
- the outer core portion but also the inner core portion may be composed of a mixture of a magnetic material and a resin.
- the reactor of the present invention can be used as a component of a power conversion device such as a converter mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, or a fuel cell vehicle, or an air conditioner.
- a power conversion device such as a converter mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, or a fuel cell vehicle, or an air conditioner.
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Abstract
Description
このリアクトルでは、コイル及び内側コア部の少なくとも一方に対する放熱構造がケースの内壁面に設けられている。このため、コイルの外側がコア材で覆われている場合でも、ケース内の放熱構造により、コイル及び内側コア部の少なくとも一方の放熱性を高めることができる。
コア204がコイル201と接触する箇所には、両者間の絶縁性をより高めるために絶縁物を介在させることが好ましい。例えばコイル201の内・外周面に絶縁性テープを貼り付けたり、絶縁紙や絶縁シートを配置したりする。内側コア部202の外周に絶縁性材料からなるボビンを配置してもよい。ボビンの構成材料には、ポリフェニレンスルフィド(PPS)樹脂、液晶ポリマー(LCP)、ポリテトラフルオロエチレン(PTFE)樹脂などの絶縁性樹脂が好適に利用できる。
特に、リアクトル101では、コイル201の全体を外側コア部203に覆われる形態とすることで、外側コア部203の形成が容易である上に、コイル201の保護を十分に図ることができる。このようにリアクトル101は、様々な利点を有する。
伝熱部206の素材としては、アルミニウムの他、アルミニウム合金などのその他の金属材料や、窒化珪素、アルミナ、窒化アルミニウム、窒化ホウ素、炭化珪素などのセラミックスを用いることができる。熱伝導率の高い伝熱部206が外側コア部203などを(ほとんど)介さずにコイル201及び内側コア部202と接触(又は近接)するので、リアクトル101内部の熱が効果的に放散される。なお、伝熱部206をリブとしても用いる場合には、機械的強度も考慮して伝熱部206の素材を選択する必要がある。
その状態でケース103内に、外側コア部203を構成する磁性材料とバインダ樹脂との混合流体を適宜流し込む。このように、外側コア部203を磁性材料と樹脂との混合物を充填することにより形成するので、ケース103の内壁面207が放熱構造により複雑な形状を有していても、その放熱構造に応じて外側コア部203を構成することができ、リアクトル101は、比較的容易に製造することができる。
なお、今回開示された実施の形態および実施例は、全ての点で例示であって制限的なものではないと考えられるべきである。本発明の範囲は、上記した説明でなく特許請求の範囲によって示され、特許請求の範囲と均等の意味および範囲内のすべての変更が含まれることが意図される
102 コンバータケース
103 リアクトルのケース
201 コイル
201A,201B コイル素子
201w 巻線
202 内側コア部
203 外側コア部
204 コア
206、401、501、601、701、1001、1004 伝熱部
206A、206B 突出部
207、801、901 内壁面
208 外壁面
209、210、211、212 側壁
301 ケースの底面
1002 外壁の放熱構造
1003 ケースの蓋
Claims (5)
- コイルと、前記コイルの内側に配置される内側コア部、及び前記コイルの外側を覆う外側コア部を有するコアと、前記コイル及びコアを収容するケースとを備えたリアクトルであって、
前記ケースが、前記コイル及び前記内側コア部の少なくとも一方に対する放熱構造を内壁面に有するリアクトル。 - 前記放熱構造が、前記ケースの内壁面の一部を突出させた伝熱部を含む請求項1に記載のリアクトル。
- 前記放熱構造が、前記ケースの外壁面と非相似形であり、前記コイル及び前記内側コア部の少なくとも一方の外形に合わせて形成された内壁面により構成される請求項1に記載のリアクトル。
- 前記コアの少なくとも前記外側コア部が磁性材料と樹脂との混合物により形成される請求項1~3のいずれか1項に記載のリアクトル。
- 前記コイルが、前記コイルの軸方向を前記ケースの底面と略平行にして配置されている請求項1~4のいずれか1項に記載のリアクトル。
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US13/522,175 US8525629B2 (en) | 2010-01-20 | 2011-01-08 | Reactor |
JP2011550875A JPWO2011089941A1 (ja) | 2010-01-20 | 2011-01-08 | リアクトル |
EP11734548.8A EP2528073B1 (en) | 2010-01-20 | 2011-01-08 | Reactor |
CN201180006195.5A CN102714091B (zh) | 2010-01-20 | 2011-01-08 | 电抗器 |
US13/954,586 US8618899B2 (en) | 2010-01-20 | 2013-07-30 | Converter and power conversion device |
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US13/954,586 Continuation-In-Part US8618899B2 (en) | 2010-01-20 | 2013-07-30 | Converter and power conversion device |
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JP2017522724A (ja) * | 2014-06-19 | 2017-08-10 | エスエムエイ ソーラー テクノロジー アクティエンゲゼルシャフトSMA Solar Technology AG | 金属インダクタハウジングに熱的に結合された少なくとも1つのインダクタコイルを備えるインダクタ組立体 |
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Also Published As
Publication number | Publication date |
---|---|
US8525629B2 (en) | 2013-09-03 |
CN102714091B (zh) | 2015-05-20 |
EP2528073A4 (en) | 2014-04-16 |
EP2528073A1 (en) | 2012-11-28 |
US20120299678A1 (en) | 2012-11-29 |
JPWO2011089941A1 (ja) | 2013-05-23 |
EP2528073B1 (en) | 2018-11-14 |
CN102714091A (zh) | 2012-10-03 |
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