JP5353618B2 - Reactor iron core parts - Google Patents

Description

  The present invention relates to a core part for a reactor.

An iron core made of a laminate in which soft magnetic steel plates are laminated is widely used for reactors and the like. In general, conventional iron cores are constructed by laminating and bonding steel plates (core materials) obtained by punching into a block-shaped laminate, and assembling a plurality of such laminates so that a magnetic path is formed. Is done. In the manufacturing process of the reactor that involves the assembly of such a laminated body, it is necessary to assemble the laminated bodies with the gap material sandwiched between them, and also to install the coil between them, so that the number of processes is large and the entire operation is complicated. It is difficult to attach the gap material with high accuracy, and an attachment failure that causes vibration is likely to occur.
In order to make it easy to assemble a plurality of laminates or to form gaps in order to solve such problems, a technique in which a laminate is housed in a resin iron case to form an iron core. Is disclosed in Patent Documents 1 and 2, for example.

JP 2002-025831 A JP 2006-202922 A

However, even the techniques disclosed in Patent Documents 1 and 2 have a large number of assembly steps until the iron core is completed, resulting in difficulty in workability, and a problem in assembly accuracy. That is, the technique of Patent Document 1 uses a pair of iron core cases (core cases) that can be coupled as shown in FIG. After inserting each one end side of a pair of laminate blocks, a coil is sheathed on this, and then each other end side of the left and right pair of laminate blocks is attached to the case coupling portion of the other iron core case. A process of plugging is required. Further, as shown in FIG. 1, the technique of Patent Document 2 includes a pair of left and right iron core cases (bobbins) in which a split core (laminate) is accommodated and a pair of upper and lower laminate cores (laminate). The process of assembling while sandwiching the gap material is necessary.
Accordingly, an object of the present invention is to provide an iron core component capable of efficiently producing a reactor with a small number of steps.

The gist of the present invention for solving the above problems is as follows.
[1] A pair of parallel columnar portions (A) in which the coils are sheathed by joining two end faces having substantially the same shape to each other, and the pair of columnar portions (A) An iron core component comprising an iron core composed of a pair of connecting portions (B) that communicate between both ends,
A resin-made iron core case (1) and an iron core member (2) housed in the iron core case (1);
The iron core case (1) is a case having an open upper surface, and at least a wall portion (10) constituting two end surfaces in the iron core axial direction, and a wall for holding the iron core member (2) from both sides thereof. parts as well as have a (11), the height of the wall portion (10) is configured lower than the height of the wall portion (11),
In the iron core case (1), a partition wall portion (12) constituting a gap of the iron core is provided, and the inner portion of the iron core case (1) is used for housing the iron core member by the partition wall portion (12). While being divided into a plurality of storage parts, the height of the partition wall part (12) is configured to be lower than the height of the wall part (11),
The iron core member (2) includes an iron core member (2a) that should constitute the columnar part (A) and an iron core member (2b) that should constitute the connecting part (B),
The core part for a reactor, wherein the wall part (10) forms a gap of the iron core in a state where it is joined to another iron core part via the wall part (10) .

[2] In the iron core component of [1], the iron core member (2) housed in the iron core case (1) is fixed to the iron core case (1) with an adhesive. Reactor iron core parts.
[3] In the iron core component of the above [2] , the inner surface of the iron core case (1) (including the wall surface when the partition wall (12) is provided) and the iron core member (2) A core part for a reactor, which is filled with an adhesive.
[4] In the iron core part according to any one of the above [1] to [3] , the two end faces in the iron core axial direction are located in the middle of the pair of columnar portions (A) of the iron core. Reactor iron core parts.
[5] In the iron core part according to any one of the above [1] to [4] , two end faces in the iron core axial direction may be connected to an end face of another iron core part or other A reactor core part for a reactor, characterized by having an engaging portion for aligning with an end face of the core part.
[6] In the iron core part according to any one of [1] to [5] , an opening is formed on the lower surface of the iron core case (1) or the lower surface is opened. Iron core parts.

[7] A method for manufacturing a reactor using the iron core part according to any one of [1] to [6] above,
Two iron core parts _{(x 1), (x 2} ) after the outer coil (Y), both iron core parts (x _1), and joined butt two end faces each other of (x ₂₎ The manufacturing method of the reactor characterized by comprising an iron core (X).
In the manufacturing method of [8] above [7], for the iron core component _{(x 1),} after or during bonding to bond the _{(x 2),} for iron core component _{(x 1),} the iron core _{(x 2)} Each core part (x ₁ ), (x ₂ ) is made by injecting and solidifying a resin constituting the heat dissipation material into the space surrounded by the wall (11) on the members (2a) and (2b). , The heat dissipating material integrally covers the iron core members (2a) and (2b) beyond the partition wall portion (12) whose height is lower than that of the wall portion (11), and both iron core components (x ₁ ), (X ₂ ), wherein the heat dissipating material is connected and integrated over the wall (10) whose height is lower than that of the wall (11).
[9] A reactor using the iron core part of any one of [1] to [6] above,
Two iron core parts (x ₁ ), (x ₂ ) are joined by abutting their two end faces and joined to each other, and a columnar part (A) of the iron core (X) ) Having a coil (Y) sheathed on the reactor.
[10] In the reactor of [9] above, a heat dissipation material is provided in a space surrounded by the wall portion (11) on the iron core members (2a) and (2b) of the iron core components (x ₁ ) and (x ₂ ). The heat-dissipating material is mounted by injecting and solidifying the resin that constitutes the partition, and in each of the iron core parts (x ₁ ) and (x ₂ ), the heat-dissipating material is a partition whose height is lower than that of the wall (11). The iron core members (2a) and (2b) are integrally covered beyond the wall (12), and the heat dissipating material of both iron core parts (x ₁ ) and (x ₂ ) Reactor characterized by being connected and integrated over a wall (10) having a height lower than that.

  By using the iron core parts of the present invention, a reactor can be constructed simply by attaching a coil to two iron core parts having substantially the same shape, and butting and joining the end faces. A reactor can be manufactured with the minimum number of steps.

The perspective view which shows one Embodiment of the components for iron cores of this invention Plan view of the iron core component of the embodiment of FIG. 1 is a perspective view showing an iron core case and an iron core member in an exploded state in the iron core component of the embodiment of FIG. The top view which shows other embodiment of the components for iron cores of this invention The top view which shows the iron core of the reactor comprised combining the components for iron cores of this invention The graph which shows the result of having investigated the thermal time constant at the time of the heating in the case where the iron core member and the iron core case are fixed with an adhesive and not when the iron core component of the present invention is fixed The graph which shows the result of having investigated the thermal time constant at the time of heat dissipation when the iron core member and the iron core case are fixed with an adhesive and when not fixing the iron core component of the present invention The graph which shows the result of having measured the noise frequency response and the noise value (A characteristic) about the reactor manufactured using the components for iron cores of this invention Explanatory drawing which shows the measurement position in the noise measurement of FIG.

1 to 3 show an embodiment of an iron core part according to the present invention. FIG. 1 is a perspective view, FIG. 2 is a plan view, and FIG. 3 is an exploded view of an iron core case and an iron core member. It is a perspective view shown. In addition, what is shown with a virtual line in FIG. 2 is another iron core part to be coupled.
As shown in FIG. 2 and FIG. 5, the iron core component of the present invention is obtained by joining two substantially identical shapes (iron core components x ₁ , x ₂ ) with their end faces butted together. An iron core X composed of a pair of parallel columnar portions A on which the coil Y is sheathed and a pair of connecting portions B communicating between both ends of the pair of columnar portions A is configured. It is.
This iron core component includes a resin iron core case 1 and an iron core member 2 (2a, 2b) housed in the iron core case 1.

The iron core case 1 has at least a wall portion 10 that forms two end faces in the iron core axis direction, and a wall portion 11 that holds the iron core member 2 from both sides thereof. The iron core case 1 of the present embodiment is a case having an open top surface that has a substantially J-shaped planar shape as a whole, and the planar shape has the wall portions 10 at both ends of a substantially J-shaped case body. Yes. In a state where the iron core components of the present invention are joined via the wall portion 10, the wall portion 10 constitutes a gap of the iron core.
The interior of the iron core case 1 is divided into a plurality of storage portions for storing iron core members by partition walls 12 that form a gap of the iron core. In this embodiment, the plane that should form the columnar portion A is divided. a holding section 14a ₁ to 14A ₃ for accommodating a rectangular iron core member 2a, is divided iron core member 2b of the flat U-shaped for constituting contact portions B in the accommodating portion 14b for accommodating.

As will be described later, in order to improve the heat dissipation of the iron core, a plurality of iron core members 2a that should constitute the columnar part A and the upper part of the iron core member 2b that should constitute the connecting part B are integrally covered with a heat dissipation material. For this reason, in this embodiment, the height of the partition wall portion 12 between the storage portions 14a _{1 to} 14a ₃ and 14b is made lower than the height of the iron core case 1 (outer wall portion), and a plurality of iron core members A heat radiating material (resin or the like) wraps around the entire upper part of 2a and the iron core member 2b so that it can be covered integrally with the heat radiating material. Further, the partition wall portion 12 has a height such that the upper surface thereof is substantially flush with the upper surfaces of the inserted iron core members 2a and 2b.
In addition, as shown in FIG. 3, the iron core component of this embodiment is mounted with a heat dissipation material (heat dissipation) when or after two substantially identical shapes (iron core components x ₁ , x ₂ ) are bonded. On the premise that the resin constituting the material is injected into the upper surface of the iron core member and then solidified), the height of the wall portions 10 at both ends is made lower than the height of the iron core case 1 (outer wall portion) The heat dissipating materials of the core parts x ₁ and x ₂ can be integrated.
From the viewpoint of heat dissipation, the thickness of the iron core case 1 is preferably as thin as possible after satisfying the required strength. From the design point of view of isotropic heat dissipation, the thickness of the bottom portion of the iron core case 1 and the thickness of the wall portion 11 so that the positional relationship between the iron core and the windings constituting the coil is symmetric. It is preferable to make the lengths approximately equal.

At two end portions in the iron core axis direction where the wall portion 10 is formed, a connecting portion 13 for connecting (joining) with an end portion of another iron core component is provided. Of the two end portions in the iron core axial direction, the connecting portion 13 at one end portion is composed of a pair of plate portions 130 projecting on both sides of the wall portion 10, and the connecting portion 13 at the other end portion. Is constituted by a step portion 131 fitted inside the pair of plate portions 130. In addition, it may replace with such a connection part 13 and may provide the engaging part for aligning with the end surface of other components for iron cores.
In addition, from the viewpoint of ensuring accuracy, it is preferable to provide the connecting portion 13 and the engaging portion as described above to join the iron core components together. Without being provided, the two end portions in the iron core axis direction may be butted together and bonded by an adhesive, or may be joined by fastening the iron case 1 with a band or the like. Also good.

Moreover, what is necessary is just to select resin which comprises the iron core case 1 suitably from viewpoints, such as heat resistance and intensity | strength. For example, polyphenylene sulfide resin (PPS resin), polybutylene terephthalate resin (PBT resin), nylon, or the like can be used. From the viewpoint of heat dissipation, it is preferable to use a resin with high thermal conductivity. For example, carbon or alumina may be mixed into the resin.
Each of the storage portions 14a _{1 to} 14a ₃ stores a flat rectangular iron core member 2a that should form the columnar portion A, and the storage portion 14b has a flat U-shape that should form the connecting portion B. The iron core member 2b is accommodated. In the present embodiment, the iron core members 2a and 2b are configured by a laminated body (block) in which punched steel plates are stacked. For example, the iron core members 2a and 2b may be configured by a pressed iron core, a dust core, ferrite, amorphous, or the like. Good. Further, the iron core members 2a and 2b may be the same material or different materials.
In addition, in embodiment, such as FIGS. 1-3, it has become "the lamination direction of the iron core member 2 = the height direction of the iron core case 1," but the lamination surface is iron in the lamination direction. Therefore, from the viewpoint of heat dissipation and productivity, “the stacking direction of the iron core member 2 = the width direction of the iron core case 1” (that is, FIG. 3 may be a state in which the iron core member 2a shown in Fig. 3 is rotated 90 degrees about the iron core axis.

The mounting of the heat radiating material (the step of injecting the resin constituting the heat radiating material into the upper surface of the iron core member and solidifying it) is normally performed as shown in FIG. 2 with two iron core components x ₁ , x ₂ having substantially the same shape. This is performed at the time of joining or after joining. In the present embodiment, there is enclosed space accommodating portion 14a ₁ to 14A _3, the iron core member 2a, which is loaded into the 14b, the wall portion 11 on the 2b, and, housing portion 14a ₁ to 14A _3, since the height of the partition wall portion 12 between 14b is lower than the wall portion 11, by the resin constituting the heat radiating member in the space is injected (filled), storage section 14a ₁ to 14A _3, the iron core in the 14b The members 2a and 2b are integrally covered with the heat dissipation material. In addition, since the height of the wall portion 10 is lower than that of the wall portion 11, when the two iron core components x ₁ and x ₂ are joined or after joining, a heat dissipating material is attached so that both the iron core components are used. The heat dissipating materials of the parts x ₁ and x ₂ are connected and integrated.

Iron core member 2a of the thus accommodating portion 14a ₁ to 14A _3, in 14b, by 2b is integrally covered with the heat radiation member, for example, cooling means the heat radiation member surface of the iron core member 2b in the accommodating portion 14b in by cooling, the iron core member 2a of the holding section 14a ₁ to 14A ₃ which direct cooling is difficult to become the inner coil can also facilitate heat dissipation. There is no particular restriction on the means for cooling the heat dissipation material surface of the iron core member 2b. For example, a heat removal member (heat sink) made of a metal having high thermal conductivity such as copper or aluminum is brought into contact with the heat dissipation material surface. It can be set as a structure.

In addition, the mounting form of the heat dissipation material is not limited to the above form,
The height of the housing portion 14a ₃ and the housing portion 14b between the partition wall portion 12 of the higher than the other partition walls 12, only iron core member 2a of the holding section 14a ₁ to 14A ₃ covering integrally from a radiation material You may be made to be.
In addition, as described above, the mounting of the heat dissipation material is generally performed when or after the two iron core components x ₁ and x ₂ are bonded. Also good. In this case, for example, a heat removal member (heat sink) may be attached to the heat dissipation material surface of the iron core member 2b.
As the heat radiating material, for example, a resin such as a silicone resin, graphite-based grease, or acrylic-based grease is used. Moreover, you may use the adhesive agent etc. which are filled between each steel plate which comprises the iron core member 2, or between the iron core member 2 and the iron core case 1. FIG.

FIG. 4 is a plan view showing another embodiment of the iron core component of the present invention.
In the embodiment of FIGS. 1 to 3, two end faces (wall portions 10) in the iron core axial direction are located at the ends of the pair of columnar portions A of the iron core, whereas in FIG. In the embodiment, two end surfaces (wall portions 10) in the iron core axial direction are located in the middle of the pair of columnar portions A of the iron core. Therefore, in this embodiment, the inside of the iron core case 1 accommodates the flat rectangular iron core member 2a that should constitute a part of one columnar portion A by the partition wall portion 12 that constitutes the gap of the iron core. Storage portion 14a ₁ , 14a ₂ to be stored, storage portion 14b to store the flat U-shaped iron core member 2b to form the connecting portion B, flat rectangular iron core to form a part of the other columnar portion A the housing portion 14a ₃ for housing the member 2a, is divided, respectively.

In such a structure, the two end surfaces (wall portion 10) in the iron core axial direction are located inside the coil Y that is externally mounted on the columnar portion A, and thus the thickness of the wall portion 10 that constitutes the gap. Even if is large, magnetic flux leakage hardly occurs. Therefore, the thickness of the wall portion 10 can be sufficiently taken (for example, the same as the thickness of the wall portion 11), which is preferable in terms of securing the strength of the iron core case 1 and manufacturability.
In addition, as another embodiment, it is good also as a structure where two end surfaces (wall part 10) in an iron core axial direction are located in the center of a pair of columnar part A of an iron core.

  In the iron core component in which the iron core member 2 is housed in the iron core case 1, vibration is likely to occur due to the gap between the iron core member 2 and the iron core case 1, and heat dissipation is also likely to be lowered. In addition, when the iron core member is a laminate, the gap between the steel plates constituting the iron core member also causes vibration and heat dissipation. For this reason, the iron core member 2 housed in the iron core case 1 is preferably fixed to the iron core case 1 with an adhesive. In particular, the inner surface of the iron core case 1 (provided that a partition wall portion 12 is provided). The adhesive is filled between the core member 2 and the iron core member 2. Moreover, when the iron core member 2 is a laminated body, it is preferable that an adhesive is filled also between the steel plates which comprise a laminated body. As described above, the gap between the iron core member 2 and the iron core case 1, and further, the gap between the steel plates constituting the iron core member 2 is filled with the adhesive so that the gap is eliminated. Since it is fixed integrally, it is possible to obtain an iron core component that is low in vibration, low in noise, and excellent in heat dissipation.

In order to fill the gap between the iron core member 2 and the iron core case 1, and further the gap between the steel plates constituting the iron core member 2, the iron core member 2 is changed to the iron core case 1. In an inserted state, uncured adhesive is present between the iron core member 2 and the iron core case 1 and between the steel plates constituting the iron core member 2, and then the adhesive is cured. It is preferable.
Here, the uncured adhesive means an adhesive having fluidity. For example, in the case of a thermosetting adhesive, it is maintained in an uncured state unless heat is applied. On the other hand, for room temperature curable adhesives, for example, in the case of UV curable adhesives, each is maintained in an uncured state unless UV light is irradiated, and in the case of anaerobic adhesives, unless air is shut off. Is done. Moreover, in the case of a cyanoacrylate-based instantaneous adhesive, by preventing contact with moisture, it is maintained in a state before starting crosslinking (uncured state).

In order to make an uncured adhesive exist between the iron core member 2 and the iron core case 1 and between the steel plates constituting the iron core member 2, at least one of the following (a) to (c) is performed. Good. Of course, the following (A) to (C) may be implemented in combination of two or more thereof. By adopting these methods, the uncured adhesive penetrates by capillarity between the iron core member 2 and the iron core case 1 and between each steel plate constituting the iron core member 2.
(A) An adhesive is put in the iron core case 1 before the iron core member 2 is inserted.
(B) An adhesive is attached to the iron core member 2 and / or the steel plate before being inserted into the iron core case 1.
(C) After the iron core member 2 is inserted into the iron core case 1, an adhesive is poured into the iron core case 1.

In order to set the iron core member 2 in the iron core case 1, when the iron core member 2 is a laminated body, the iron core member 2 is partially bonded temporarily with an adhesive between the steel plates. The iron core member 2 may be prepared in advance and inserted into the iron core case 1 (laminated body housing portion), or a steel plate that constitutes the iron core member 2 may be inserted into the iron core case 1 (housing). The iron core member 2 may be formed in the iron core case 1 by sequentially inserting into the portions 14a _{1 to} 14a ₃ , 14b). In either case, the iron core member 2 is in a state of being inserted so as to substantially fit into the iron core case 1.

  The iron core member 2 (laminated body) in which the steel plates are partially temporarily bonded with an adhesive is obtained, for example, by sequentially stacking steel plates coated with dots in several places. In the production line of general iron core members (laminates), adhesive is partially applied to the steel plate part to be punched in advance or at the same time as the punching (for example, it is applied in the form of dots in several places), and the punched steel plates are sequentially By superimposing, the iron core member 2 in which the steel plates are partially temporarily bonded with an adhesive is obtained.

  From the viewpoint of efficiently allowing the adhesive to penetrate between the iron core member 2 and the iron core case 1 and between the steel plates constituting the iron core member 2 among the methods (a) to (c) above. The methods (a) and (b) are advantageous, while the method (c) is advantageous from the viewpoint of workability. Further, in any of the methods (A) to (C), in order to appropriately penetrate the adhesive into the gaps between the steel plates constituting the iron core member 2 and between the steel plates constituting the iron core member 2, It is particularly preferred to utilize vacuum impregnation. In carrying out this vacuum impregnation, in the case of (a), after the iron core member 2 is inserted into the iron core case 1 containing the adhesive, the whole iron core case 1 is evacuated. In the case of (b), the iron core member 2 is vacuum-impregnated with an adhesive and then inserted into the iron core case 1. In the case of (c), an adhesive is poured into the iron core case 1 in which the iron core member 2 is inserted, and then the whole iron core case 1 is evacuated.

In order to improve the heat dissipation of the iron core, the following configuration is preferable.
(A) The space above the iron core member 2 inserted in the iron core case 1 is filled with a heat dissipation material, and the iron core member 2 is covered with the heat dissipation material.
(B) An opening is formed on the lower surface (bottom surface) of the iron core case 1 or the lower surface is opened.
The configuration (a) is as described above.
Further, the configuration of (b) has a structure in which the upper surface of the iron core case 1 is opened and the opening is formed on the lower surface or the lower surface side is opened, as compared with the structure in which only the upper surface of the iron core case 1 is opened. This is because it is more advantageous in terms of heat dissipation. When manufacturing such an iron core part, when an uncured adhesive is present in the iron core case 1, the lower surface of the iron core case 1 is placed on the base to prevent the adhesive from leaking from the lower surface side. Then, the adhesive and the iron core member 2 are injected and charged.

Next, the manufacturing method of the reactor using the iron core components of the present invention and the manufactured reactor will be described.
In this manufacturing method, as shown in FIG. 5, two iron core parts x ₁ and x ₂ of the present invention should be prepared, and the iron core parts x ₁ and x ₂ should become iron core pillars A. moiety (i.e., the portion of the housing portion 14a ₁ to 14A ₃ accommodating the iron core member 2a) on which the outer coil Y to, and how the two end faces of the iron core parts _{x 1, x 2} (wall 10) Are joined together via the connecting portion 13 to obtain a reactor. In other words, the reactor is basically completed only by the process of sheathing the coil Y on each of the iron core parts x ₁ and x ₂ and the process of joining the end surfaces of both iron core parts x ₁ and x ₂ together. Can be made.
Incidentally, between two end faces of the iron core parts x _1, x ₂ (wall 10) may be adhesively bonded.

Further, when or after joining the iron core parts x ₁ and x ₂ , mounting of the heat dissipation material as described above (step of injecting the resin constituting the heat dissipation material into the upper surface of the iron core member and solidifying it) You may go.
The reactor manufactured in this way includes two iron core components x ₁ and x ₂ that are joined by butting two end surfaces of each other, and a columnar portion of the iron core X. It has a coil Y sheathed on A.
The two iron core parts x ₁ and x ₂ used to manufacture the reactor may be determined in advance or may be combined randomly.

The following iron core parts having the structure shown in FIGS. 1 to 3 were manufactured.
-Iron core parts (i): Iron core member and iron core case fixed with an adhesive 250 steel plates obtained by punching a thin steel strip (6.5% silicon with a thickness of 0.1 mm) After applying an acrylic thermosetting adhesive on both sides of the steel sheet (applying by dipping), the steel core case 1 (made of PPS resin containing 30% by weight of glass filler) is sequentially fitted and charged, and the iron core is inserted. Members 2a and 2b (both have a space factor of about 93%) were constructed.
The size of the steel plate for the iron core member 2a was 20 mm × 14 mm, and the steel plate for the iron core member 2b was U-shaped with a width of 20 mm. The size of the iron core case 1 was set to 75 mm × 60 mm × 32 mm with the maximum outer dimensions (length × width (U-shaped portion width) × height). The amount of adhesive applied was 2 g for each iron core member 2a and 3 g for the iron core member 2b.

As described above, the iron core case 1 in which a plurality of steel plates were inserted and the iron core members 2a and 2b were formed therein was held at 150 ° C. for 1 hour to cure the adhesive. In this heating step, the temperature was raised stepwise (normal temperature → 60 ° C. → 100 ° C. → 150 ° C.) in order to prevent bubbles from appearing in the adhesive. Thus, the iron core part (i) was manufactured.
-Iron core parts (ii): Iron core member and iron core case not fixed with adhesive The same number of steel plates as above are fitted into the iron core case 1 without applying adhesive. By doing so, the iron core members 2a and 2b were constituted, and the iron core part (ii) was manufactured.

With respect to the two iron core parts (i) and (ii) obtained as described above, the heat dissipation was measured by the following method.
The iron core component was heated with a heat source (hot plate) at 150 ° C., and the temperature change between the surface of the iron core (iron core member 2) and the surface of the iron core case 1 was measured. When the surface temperature of the iron core parts was completely saturated, the product was removed from the heat source, dissipated in the air, and the temperature change at that time was measured. The temperature change during heating and heat dissipation can be expressed by the following formulas (1) and (2). Fitting the obtained data to formulas (1) and (2) using the least square method, The time constant and the thermal time constant during heat dissipation were determined.

  FIG. 6 (thermal time constant during heating) and FIG. 7 (thermal time constant during heat dissipation) show the results. According to this, it can be seen that the thermal conductivity in the stacking direction of the iron core component (i) is improved by the adhesive filled between the steel plates. Moreover, since the adhesive is also filled between the iron core (iron core members 2a, 2b) and the iron core case 1, it can be seen that the thermal conductivity from the iron core to the iron core case is also improved. Since the same degree of thermal conductivity is obtained in both the in-plane direction and the laminating direction of the steel sheet, the heat generated in the iron core due to iron loss is not only radiated directly from the iron core to the air, It can be seen that heat is properly radiated into the air even through the lead case.

  Next, a reactor was manufactured using the iron core parts (i) and (ii) described above. A pair of each iron core part was prepared, the pair of iron core parts were joined, and a coil was attached to form a reactor. The coil used was an air-core shape in which 1 PEW wire was wound in a square shape for 30 turns. The connecting portion 13 and the wall portion 10 of the pair of iron core cases were bonded and fixed with an adhesive. This reactor has a sine wave shape with a peak value of 0 to 12A, supplies a current that fluctuates at an excitation frequency of 1 to 20 kHz, and measures the noise frequency response and noise value (A characteristic) generated for each excitation frequency. did. The result is shown in FIG. As shown in FIG. 9 (FIG. 9 (a) is a plan view and FIG. 9 (b) is a side view), the noise measurement position was 5 mm above the iron core component.

In FIG. 8, the curve is the frequency response, and the plot is the 10 kHz to 20 kHz overall of the noise value (A characteristic). According to this, it turns out that the noise by the reactor by iron core components (i) is effectively suppressed in the range of 14 kHz-17 kHz compared with the thing of iron core components (ii). Details of the noise values of the iron core parts (i) and (ii) are as follows.
14kHz Iron core parts (i): 60.8dB Iron core parts (ii): 72.9dB
15 kHz Iron core parts (i): 69.4 dB Iron core parts (ii): 79.4 dB
17 kHz Iron core parts (i): 68.5 dB Iron core parts (ii): 83.2 dB

  In the iron core component (i), the air layer is eliminated by filling the adhesive between the steel plates constituting the iron core member 2 and between the iron core member 2 and the iron core case 1, which is caused by magnetostrictive vibration. The propagation of noise is suppressed, the steel plates constituting the iron core member 2 are joined together by an adhesive, the iron core member 2 and the iron core case 1 are also joined, and the whole is integrated to generate vibration itself. As a result, it is considered that noise was effectively suppressed.

1 iron core casing 2, 2a, 2b iron core members 10 and 11 the wall portion 12 partition wall portion 13 connecting portion 14a ₁ to 14A _3, 14b accommodating portion 130 plate portion 131 stepped portion X iron core x _{1, x 2} for iron core Parts Y Coil A Column part B Connection part

Claims (10)

A pair of parallel columnar portions (A) on which the coils are sheathed and joined between two end portions of the pair of columnar portions (A) by joining two substantially identical shapes while butting their end faces together An iron core part composed of a pair of connecting parts (B) that communicate with each other,
A resin-made iron core case (1) and an iron core member (2) housed in the iron core case (1);
The iron core case (1) is a case having an open upper surface, and at least a wall portion (10) constituting two end surfaces in the iron core axial direction, and a wall for holding the iron core member (2) from both sides thereof. And the height of the wall (10) is lower than the height of the wall (11).
In the iron core case (1), a partition wall portion (12) constituting a gap of the iron core is provided, and the inner portion of the iron core case (1) is used for housing the iron core member by the partition wall portion (12). While being divided into a plurality of storage parts, the height of the partition wall part (12) is configured to be lower than the height of the wall part (11),
The iron core member (2) includes an iron core member (2a) that should constitute the columnar part (A) and an iron core member (2b) that should constitute the connecting part (B),
The core part for a reactor, wherein the wall part (10) forms a gap of the iron core in a state where it is joined to another iron core part via the wall part (10).   The core component for a reactor according to claim 1, wherein the iron core member (2) housed in the iron core case (1) is fixed to the iron core case (1) with an adhesive. .   An adhesive is filled between the inner surface of the iron core case (1) (including the wall surface when the partition wall (12) is provided) and the iron core member (2). The reactor core part for a reactor according to claim 2.   The core part for a reactor according to any one of claims 1 to 3, wherein two end faces in the iron core axial direction are located in the middle of the pair of columnar portions (A) of the iron core.   It has an engaging part in order to align with the connection part for connecting with the end surface of other iron core components, or the end surface of other iron core components in two end surfaces in an iron core axis direction The core part for reactors according to any one of claims 1 to 4.   The core part for a reactor according to any one of claims 1 to 5, wherein an opening is formed on the lower surface of the iron core case (1) or the lower surface is opened. A method for manufacturing a reactor using the iron core part according to claim 1,
Two iron core parts _{(x 1), (x 2} ) after the outer coil (Y), both iron core parts (x _1), and joined butt two end faces each other of (x ₂₎ The manufacturing method of the reactor characterized by comprising an iron core (X). Wall portions on the iron core members (2a) and (2b) of the iron core components (x ₁ ) and (x ₂ ) when or after joining the iron core components (x ₁ ) and (x ₂ ) By injecting and solidifying the resin that constitutes the heat dissipation material into the space surrounded by (11), the heat dissipation material is more than the wall portion (11) in each of the iron core parts (x ₁ ) and (x ₂ ). The iron core members (2a) and (2b) are integrally covered beyond the partition wall portion (12) having a low height, and the heat dissipating materials of both iron core components (x ₁ ) and (x ₂ ) are: The method for manufacturing a reactor according to claim 7, wherein the reactor is connected and integrated over a wall (10) having a height lower than that of the wall (11). A reactor using the iron core component according to claim 1,
Two iron core parts (x ₁ ), (x ₂ ) are joined by abutting their two end faces and joined to each other, and a columnar part (A) of the iron core (X) ) Having a coil (Y) sheathed on the reactor. Injecting the resin constituting the heat dissipation material into the space surrounded by the wall (11) on the iron core members (2a) and (2b) of the iron core components (x ₁ ) and (x ₂ ) and solidifying them. heat dissipating material is mounted, the respective iron core parts (x _1), the iron core member beyond the (x _2), said heat radiating member is a partition wall is lower in height than the wall portion (11) (12) (2a), (2b) are integrally covered, and the heat dissipating material of both iron core parts (x ₁ ), (x ₂ ) has a lower wall part (10) than the wall part (11) The reactor according to claim 9, wherein the reactor is connected and integrated.

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