JP5964572B2 - Method for manufacturing insert molded core for coil device, method for manufacturing ring core unit for coil device, method for manufacturing coil device, and coil device - Google Patents

Description

  The present invention relates to a coil device such as a reactor mounted on a drive system of an automobile, a method for manufacturing an insert-molded core for a coil device, a method for manufacturing a ring core unit for a coil device, and a method for manufacturing a coil device.

  Large-capacity coil devices (for example, reactors) used in hybrid vehicle and electric vehicle drive systems generate a lot of heat due to iron loss and copper loss at high loads, and continue to use the generated heat without releasing it to the outside. Then, the core and the coil are overheated and the electromagnetic characteristics are deteriorated. Therefore, in such a coil device, generally, a main body portion including a core and a coil is housed and fixed in a heat radiating case formed of a metal having good thermal conductivity such as an aluminum alloy. When fixing the main body, the gap between the main body and the heat radiating case (air layer) is filled with a filler such as resin in order to efficiently release the heat of the core and the coil to the outside. The heat generated in the core and coil is released to the outside through the filler and the heat dissipation case.

  However, this type of coil device is configured such that a terminal block for fixing the coil terminal is attached to the outer peripheral position of the heat dissipation case, and thus the overall size of the device is large. Therefore, when the coil device is installed in an automobile drive system or the like, a large space is required for the installation. In addition, for example, a plurality of components (heat radiation case, terminal block fixture, terminal block, terminal, etc.) are provided between a reference position (mounting hole formed in the heat radiation case) and a terminal for attaching the coil device to the drive system. Is intervening. For this reason, if the tolerances of the components are stacked, it is difficult to accurately obtain the terminal position with respect to the reference position. In addition, the cost of the filler is high, and there is a problem that a large installation place is required because the equipment for filling requires a great initial investment and the scale of the equipment is large.

  Therefore, Patent Document 1 proposes a coil device having a configuration that does not require a heat dissipation case. In patent document 1, when installing the reactor which consists of a core and a coil in a cooler, in the state which applied metal blocks, such as aluminum, to the lower surface of a core, the whole product which consists of the metal block and a reactor is almost completely made of resin. cover. The entire product covered with the resin is fixed to the cooler via the fixture. Since the heat generated in the core is transmitted to the cooler via the metal block, the heat dissipation of the core is ensured even when there is no heat dissipation case.

JP 2007-180224 A

  However, Patent Document 1 does not describe any specific method for assembling the core and the metal block. If the core and the metal block are simply applied to each other, it is difficult to coat the entire resin with the surfaces in contact with each other with high accuracy. When the contact accuracy is low, a beat sound is generated between the core and the metal block due to vibration or magnetostriction of the core during excitation. In addition, since a resin coating is interposed between the metal block and the cooler, further beat sounds are generated between the metal block and the resin coating and between the resin block and the cooler due to the above-mentioned beat noise. There is a risk of doing. Moreover, in patent document 1, the precision of a contact with a core and a metal block is low, and it is easy to produce an air layer (high heat dissipation resistance) between them. For this reason, the efficiency of heat transfer from the core to the metal block is reduced, and overheating of the core cannot be effectively suppressed. Further, the resin coating between the metal block and the cooler may hinder efficient heat transfer from the metal block to the cooler.

  The present invention has been made in view of the above circumstances, and the object of the present invention is a case suitable for efficiently radiating heat from the core while suppressing the generation of beat noise caused by vibration and magnetostriction of the core. It is providing the manufacturing method of the coil apparatus of a less, the insert molding core for coil apparatuses, the manufacturing method of the ring core unit for coil apparatuses, and the coil apparatus manufacturing method which manufactures a coil apparatus.

  The method for manufacturing an insert-molded core for a coil device according to an aspect of the present invention includes a core and a heat-conductive block having a higher thermal conductivity than a resin, with the core being inserted in an insert-molding die for the core. By pressing the one side of the core and pressing the other side of the core against the side wall in the insert molding die by the placing step to be placed on the first mold and the first movable die movable in the left-right direction within the insert molding die The position of the core in the insert mold is determined, and the upper surface of the core is pushed by the second movable mold movable in the vertical direction in the insert mold so that the lower surface of the heat conduction block becomes the bottom surface in the insert mold. By pressing, the facing surface contact step for bringing the core and the heat conduction block into close contact with each other, the injection step for injecting molten resin into the insert mold, and the insert mold being injected into the insert mold By curing the melting resin, the method comprising a molding step of obtaining an insert molding core surface facing each other and the core and the heat conduction block by a resin coating in close contact, the.

  In this way, the heat conduction block is sandwiched between the core whose position in the insert mold is precisely determined by being biased to the side wall surface in the insert mold and the bottom surface in the insert mold. By performing the insert molding, the core and the heat conduction block are brought into close contact with each other, and the position of the heat conduction block in the insert molding core is precisely determined. Therefore, for example, when a coil device equipped with an insert-molded core is fixed to a cooler, the heat conduction block comes into surface contact with the mounting surface of the cooler with high accuracy. Thereby, the heat generated in the core and transmitted to the heat conduction block is efficiently transmitted to the cooler, and the overheating of the core is satisfactorily suppressed. In addition, it is difficult to form an air layer between the core and the heat conduction block, and there are no inclusions such as a resin layer between the heat conduction block and the cooler. Heat transfer to the cooler is efficient. In addition, since the core and the heat conduction block, and the heat conduction block and the cooler can be brought into contact with each other with almost no gap, the generation of beat sound due to the vibration and magnetostriction of the core during excitation can be suppressed satisfactorily.

  Moreover, the manufacturing method of the insert molding core for coil devices which concerns on one form of this invention includes the bus-bar installation process which installs the bus bar connected to the coil terminal of the coil apparatus which mounts a core, for example on an insert molding die. May be. In this case, an insert-molded core having a bus bar in which the root portion is insert-molded is obtained in the molding step.

  A heat conductive block is good also as a structure which has a flange part in which the hole for fixation for fixing an insert molding core to a predetermined cooler was formed. During the facing surface contact process, the flange portion is fixed at a position where the molten resin does not flow. Therefore, in the molding process, an insert molded core with the flange portion exposed is obtained.

  At least one of the opposing surfaces may have a convex shape so that only a part of the opposing surfaces of the core and the heat conduction block are in close contact with each other in the opposing surface contact step. In this case, the molten resin is injected into the gap between the opposing surfaces in the injection step, and the insert molding core in which the gap between the opposing surfaces is filled with the resin is obtained in the molding step.

  The core is, for example, a substantially U-shaped U core having two legs arranged in parallel. In this case, in the facing surface contact step, the end surfaces of the two legs are pressed against the side wall surfaces in the insert mold by the first movable mold, and the resin coating on the U core A substantially cylindrical hollow tube portion is formed by extending in a direction away from the U core beyond the end face. Further, in the molding step, for example, an insert molding core in which the lower surface of the heat conduction block and the leg end surface of the U core are orthogonal is obtained by transferring the side wall surface and the bottom surface in the insert molding die orthogonal to each other. You may do it.

  Moreover, the manufacturing method of the ring core unit for coil apparatuses which concerns on one form of this invention manufactures the ring core unit for coil apparatuses using a pair of insert molding core manufactured by the manufacturing method of the said insert molding core for coil apparatuses. An intermediate member inserting step of inserting a predetermined interposed member into the hollow cylindrical portion from the opening of each hollow cylindrical portion of the pair of insert molded cores; and a pair of insert molded cores into which the predetermined interposed member is inserted A ring core unit forming step of forming the ring core unit by butting the openings together.

  Here, the predetermined interposition member is disposed, for example, between the substantially rod-shaped I core that forms a magnetic path between the leg end surfaces of the pair of U cores, and between the U core and the I core, and between the I cores. And a gap member.

  Moreover, the manufacturing method of the coil apparatus which concerns on one form of this invention is a method of manufacturing a coil apparatus using the ring core unit manufactured by the manufacturing method of the said ring core unit for coil apparatuses, and resin coating is carried out among ring core units. A coil winding step of winding the coil around the outer periphery of the core-internal portion where the core is embedded.

  In addition, in the method for manufacturing a coil device according to an aspect of the present invention, a heat dissipation sheet that fills a step between the lower surface of the heat conduction block that is a non-resin-coated region and the lower surface of the outer periphery of the coil is provided on the lower surface of the outer periphery of the coil. It is good also as a method including the thermal radiation sheet | seat close_contact | adherence process to stick.

  Moreover, the manufacturing method of the coil apparatus which concerns on one form of this invention is good also as a method including the bus-bar connection process which connects a coil terminal to a bus bar.

  Moreover, the coil apparatus which concerns on one form of this invention is provided with the insert shaping | molding core resin-coated by insert molding, and the coil which winds the outer periphery of an insert molding core from resin coating. The insert-molded core includes a core and a heat conductive block that is in close contact with the core in the resin coating and has a higher thermal conductivity than the resin. A part of the heat conduction block is exposed on the lower surface of the insert molding core that is in surface contact with a predetermined cooler.

  The coil device according to an aspect of the present invention may include a bus bar that is fixed to at least one of the insert molding cores by insert molding and connected to the terminal of the coil.

  The heat conduction block may have a flange portion that is a non-resin-coated portion. For example, a fixing hole for fixing the coil device to a predetermined cooler is formed in the flange portion.

  At least one of the mutually facing surfaces may have a convex shape so that only a part of the facing surfaces of the core and the heat conduction block are in close contact with each other. In this case, the gap between the opposing surfaces is filled with resin.

  The coil device according to one embodiment of the present invention may include a ring core unit including a pair of insert-molded cores. Each of the pair of insert-molded cores includes a substantially U-shaped U core having two legs arranged in parallel, and a heat conduction block in close contact with the U core in the resin coating. The resin coating on the U core may extend to the direction away from the U core beyond the leg end surfaces of the two legs, thereby forming a substantially cylindrical hollow cylinder. A predetermined interposition member is inserted into the hollow cylinder portion from the opening of the hollow cylinder portion, and the openings of the pair of insert molding cores into which the predetermined interposition member is inserted are abutted to each other, thereby forming a ring core unit. The insert molded core may have a configuration in which the lower surface of the heat conduction block and the leg end surface of the U core are orthogonal to each other.

  On the lower surface of the outer periphery of the coil, for example, a heat-dissipating sheet that fills a step between the lower surface of the heat conduction block that is a non-resin-covered region and the lower surface of the outer periphery of the coil is in close contact.

  According to the present invention, the core and the heat conduction block, and the heat conduction block and the cooler can be brought into contact with each other without any substantial gap, thereby suppressing the generation of the beat sound caused by the vibration and magnetostriction of the core and the core efficiently. A caseless coil device suitable for heat dissipation, a method of manufacturing an insert-molded core for a coil device, a method of manufacturing a ring core unit for a coil device, and a method of manufacturing a coil device for manufacturing a coil device are provided.

It is a top view of the coil apparatus which concerns on embodiment of this invention. It is a perspective view of the coil apparatus which concerns on embodiment of this invention. It is a side view of the coil apparatus which concerns on embodiment of this invention. It is a side view of the coil apparatus which concerns on embodiment of this invention. It is AA sectional drawing in FIG. It is a disassembled perspective view of the coil apparatus which concerns on embodiment of this invention. It is explanatory drawing of the manufacturing method of the insert molding core which concerns on embodiment of this invention, and a figure which shows the insert molding core manufactured by the said method. It is a figure which shows the insert molding core manufactured by the manufacturing method of the insert molding core which concerns on another embodiment.

  Hereinafter, a coil device according to an embodiment of the present invention will be described with reference to the drawings.

  1 and 2 are a top view and a perspective view, respectively, of a coil device 1 according to an embodiment of the present invention. 3 and 4 are side views of the coil device 1. 5 is a cross-sectional view taken along the line AA in FIG. FIG. 6 is an exploded perspective view of the coil device 1. The coil device 1 according to the present embodiment is a reactor used in, for example, a drive system for a hybrid vehicle or an electric vehicle. In the following description, the vertical direction in FIG. 1 is defined as the X direction, the horizontal direction orthogonal to the vertical direction is defined as the Y direction, and the direction orthogonal to the two vertical and horizontal directions and perpendicular to the paper surface is defined as the Z direction. Define. In addition, when using the coil apparatus 1, you may arrange | position the coil apparatus 1 toward any direction.

  As shown in FIGS. 1 to 4, the coil device 1 includes a ring core unit 10, a coil 20, and a bus bar 30. As shown in FIGS. 5 and 6, the ring core unit 10 includes insert molded cores 12 </ b> A and 12 </ b> B, a gap member 14, and an I core 16. Since the coil device 1 is a caseless type coil device that does not include a heat radiating case, it is suitable for miniaturization design. Further, with the reduction of the heat dissipation case, no filler is required. Therefore, the cost of the filler and the filling process are not required, and the capital investment for filling is not required. As a result, the manufacturing unit price of the coil device 1 can be suppressed.

  The insert-molded core 12B has a substantially U-shaped (broken line in FIG. 1) U-core 121 having two core legs 121a arranged in parallel, and a metal block 122 made of a metal having good thermal conductivity such as an aluminum alloy. Are integrally resin-coated by insert molding. For the U core 121, for example, a ferrite core is used. The ferrite core may be replaced with another soft magnetic material such as an electromagnetic steel plate or a dust core. A bus bar 30 is further integrated with the insert molding core 12A by insert molding. The structure of the insert molding cores 12A and 12B is different depending on the presence or absence of the bus bar 30. Further, the engagement shapes described later are different. However, other configurations are substantially the same.

  Fig.7 (a) is a figure for demonstrating the manufacturing method of insert molding core 12B, FIG.7 (b) is a figure which shows insert molding core 12B which is the result manufactured by the said method. In addition, the shape of the insert mold 200 for the insert-molded core 12B shown in FIG. 7A is schematic and does not faithfully reproduce the transferred shape of the insert-molded core 12B. The insert-molded core 12A is manufactured in substantially the same manner as the insert-molded core 12B, except that the bus bar 30 is inserted. Therefore, in this specification, description of the manufacturing method of insert molding core 12A is simplified with description of the manufacturing method of insert molding core 12B.

  As shown in FIG. 7A, in the manufacturing process of the insert molding core 12B, the bottom surface in the insert molding die 200 with the U core 121 and the metal block 122 overlapped in the vertical direction (Z direction). Placed on (cavity bottom) 202. The cavity of the insert mold 200 is slightly larger than the overall outer dimensions of the U-core 121 and the metal block 122 because they cover the entire resin. In the case of the insert molding core 12A, the bus bar 30 is further set at a specified position in the insert molding die (a position where only the root portion of the bus bar 30 is accommodated in the cavity).

  The insert mold 200 includes a first movable mold 204 that advances and retreats in the X direction within a sleeve formed in the fixed mold. After placing the U core 121 and the metal block 122, the first movable mold 204 moves in the X direction and pushes the core side surface 121 b of the U core 121, and the end surface (core leg portion) of each core leg 121 a of the U core 121. The end surface 121 c is pressed against the cavity side wall surface 206 (a surface orthogonal to the cavity bottom surface 202) in the insert mold 200. Thereby, the position of the U core 121 in the insert mold 200 is accurately determined.

  Next, the second movable mold 208 of the insert mold 200 is lowered in the Z direction to press the core upper surface 121 d of the U core 121 and press the block lower surface 122 a of the metal block 122 against the cavity bottom surface 202. The opposing surfaces of the U core 121 and the metal block 122 (the lower surface of the U core 121 (core lower surface 121e) and the upper surface of the metal block 122 (block upper surface) 122b) are pressed by the second movable mold 208 and the cavity. It adheres by receiving the reaction force from the bottom face 202. Note that the cavity of the insert mold 200 becomes a closed space only when the second movable mold 208 is lowered in the Z direction.

  The molten resin injected from the injection device is injected into the cavity of the insert mold 200 through the sprue, runner, and gate. When the molten resin injected and filled in the cavity is cured, an insert molding core 12B in which substantially the entire U core 121 and the metal block 122 in which the core lower surface 121e and the block upper surface 122b are in close contact with each other is integrally coated is obtained. . Also, from the insert mold 200 for the insert mold core 12A, substantially the entire U core 121 and metal block 122 in which the core lower surface 121e and the block upper surface 122b are in close contact with each other are integrally resin-coated, and the bus bar 30 is The insert molding core 12B fixed by insert molding is obtained.

  As shown in FIG. 7B, in the insert-molded core 12B, the resin portion covering each core leg 121a of the U core 121 extends beyond the core leg end face 121c in a direction away from the U core 121. Thus, a pair of hollow cylindrical portions 123 having a substantially cylindrical shape (a cylindrical shape having a substantially rectangular cross section) are formed. One end of the hollow cylindrical portion 123 is open (cylindrical portion opening 123a), and the core leg end surface 121c is located at the other end (bottom surface in the hollow cylindrical portion 123). The core leg end surface 121c located in the hollow cylindrical portion 123 is pressed against the cavity side wall surface 206 at the time of molding and the molten resin does not wrap around, so that it is not covered with resin and is an exposed surface. The block lower surface 122 of the metal block 122 is also pressed against the cavity bottom surface 202 at the time of molding, and the molten resin does not go around. In addition, the molten resin wraps around the area on the core side surface 121b to which the first movable mold 204 is applied and the area on the core upper surface 121d to which the second movable mold 208 is applied. Not in. Therefore, the non-resin-coated regions 124 (see FIG. 3) and 125 (see FIG. 1) that are not resin-coated are provided.

  As shown in FIGS. 5 and 6, each of the pair of hollow cylindrical portions 123 of the insert molding core 12 </ b> A released from the insert molding die 200 has a gap member 14 in order from the core leg end face 121 c side. The I core piece 16 and the gap member 14 are attached by bonding or the like. The gap member 14, the I core piece 16, the gap member 14, and the I core piece 16 are attached to each of the pair of hollow cylindrical portions 123 of the insert-molded core 12B in this order from the core leg end face 121c side. . Since the gap member 14 and the I core piece 16 have an outer wall surface shape that is substantially equal to the inner wall surface shape of the hollow cylinder portion 123, the gap member 14 and the I core piece 16 fit in the hollow cylinder portion 123 without a gap. The gap member 14 is, for example, a plate material made of a non-magnetic material (various ceramics such as alumina or resin). The I core piece 16 is a substantially rod-shaped magnetic body made of the same material as the U core 121, for example.

  The coil 20 has a configuration in which linear coil portions 22 and 24 having the same structure are arranged in parallel and one ends thereof are connected by a coil connecting wire 26. The linear coil portions 22 and 24 are formed by bending a flat enameled wire in a right angle direction at four locations per turn and winding it in a substantially square shape.

  As shown in FIG. 6, a claw portion 123 </ b> A extending in a direction protruding from the cylindrical opening 123 a is formed on the outer peripheral surface of the hollow cylindrical portion 123 of the insert molding core 12 </ b> A. A claw fitting portion 123B corresponding to the claw portion 123A is formed on the outer peripheral surface of the hollow cylindrical portion 123 of the insert molding core 12B. As shown in FIG. 5, the insert molding cores 12A and 12B are inserted into the hollow portions of the linear coil portions 22 and 24 so that the cylindrical opening 123a is abutted with each other. The ring core unit 10 is completed when the I core piece 16 on the molded core 12B side is bonded and fixed, and the claw portion 123A and the claw fitting portion 123B are engaged. In this way, the ring core unit 10 is bonded to the core leg end surfaces 121c of the pair of U cores 121 through a predetermined interposition member (gap member 14 and I core fragment 16), and is bonded and fixed. A closed magnetic circuit is formed.

  A resin flange 126 is formed on the surface of each insert molding core 12A, 12B. As the ring core unit 10 is completed, the linear coil portions 22 and 24 are sandwiched between the resin flanges 126 of the insert molded cores 12A and 12B, and the position with respect to the ring core unit 10 is determined. Thereby, the coil strands of the linear coil portions 22 and 24 are positioned so as to wind the closed magnetic path formed by the ring core unit 10. The lead portions 22a and 24a of the linear coil portions 22 and 24 are welded to the corresponding bus bars, respectively.

  Metal flanges 127 are formed at both ends of the metal block 122 in the Y direction. Since the metal flange 127 is fixed at a position (for example, outside the cavity) where the molten resin of the insert mold 200 does not flow during molding, it is not covered with resin. A fixing hole 127 a is formed in the metal flange 127. The coil device 1 is placed on a cooling member (for example, an inverter case) 300, and is fixed on the inverter case 300 by bolts (not shown) inserted through the fixing holes 127a.

  In the present embodiment, as described above, the U core 121 is urged against the cavity side wall surface 206 by the first movable mold 204. Since the cavity side wall surface 206 which is a part of the mold has guaranteed surface accuracy, the position of the U core 121 in the cavity is determined precisely. Next, when the U core 121 is pushed by the second movable piece 208, the metal block 122 is sandwiched between the precisely positioned core lower surface 121e and the cavity bottom surface 202 with guaranteed surface accuracy. As a result, the core lower surface 121e and the block upper surface 122b are brought into close contact with each other, and the position of the block lower surface 122a in the insert molding core 12A or 12B is precisely determined.

  Since the position accuracy of the block lower surface 122a in the insert molded core 12A or 12B is high, when the insert molded cores 12A and 12B are engaged, the respective block lower surfaces 122a are positioned on substantially the same plane. Therefore, when the coil device 1 is fixed on the inverter case 300, each block lower surface 122 a comes into surface contact with the inverter case 300 with high accuracy. Thereby, the heat generated in the U core 121 and the I core fragment 16 and transmitted to the metal block 122 is efficiently transmitted to the inverter case 300, and the overheating of the ring core unit 10 and the coil 10 is suppressed well. In addition, it is difficult to form an air layer between the U core 121 and the metal block 122 (or there is substantially no air layer), and there are inclusions such as a resin layer between the metal block 122 and the inverter case 300. Therefore, heat transfer from the U core 121 to the inverter case 300 via the metal block 122 is efficient. In addition, since the U core 121 and the metal block 122, and the metal block 122 and the inverter case 300 can be brought into contact with each other with almost no gap, it is possible to generate beat sound due to vibration and magnetostriction of the U core 121 during excitation. It can be suppressed.

  In addition, in the insert molding core 12A or 12B, the cavity side wall surface 206 and the cavity bottom surface 202 in the insert molding die 200 orthogonal to each other are transferred, so that the block lower surface 122a and each core leg portion end surface 121c are formed. Orthogonality is guaranteed. Therefore, when the core leg end faces 121c of the U core 121 in each insert molding core are opposed to each other, the block lower surface 122a of each insert molding core is positioned on substantially the same plane, and each block lower surface 122a is the inverter case 300. Therefore, the surface contact is made with high accuracy.

  In the present embodiment, the metal block 122 and the bus bar 30 are integrated by insert molding. Therefore, a terminal block for fixing the bus bar 30 is unnecessary. For example, when the fixing hole 127a is set as the reference position, there is no stacking of tolerances of a plurality of parts between the reference position and the bus bar 30, so that the positional accuracy of the bus bar 30 is guaranteed.

  Incidentally, there is a step between the block lower surface 122 of the metal block 122 and the lower surfaces of the outer circumferences of the linear coil portions 22 and 24. In the present embodiment, in order to fill this step, the heat radiation sheet 40 with good thermal conductivity is tightly fixed on each lower surface of the outer periphery of the linear coil portions 22 and 24. By bringing the heat radiating sheet 40 into close contact with the lower surfaces of the outer circumferences of the linear coil portions 22 and 24, the surface of the heat radiating sheet 40 and the block lower surface 122 are positioned on substantially the same plane. Therefore, when the coil device 1 is fixed on the inverter case 300, the surface of the heat dissipation sheet 40 is in close contact with the inverter case 300. Therefore, the heat generated in the coil 10 is efficiently transmitted to the inverter case 300 through the heat dissipation sheet 40.

  The above is the description of the exemplary embodiments of the present invention. The embodiments of the present invention are not limited to those described above, and can be arbitrarily changed within the scope of the technical idea expressed by the description of the scope of claims.

  For example, due to the shape error of the U core 121 or the metal block 122, the core lower surface 121e and the block upper surface 122b may not completely adhere to each other, and a minute gap may be formed between both surfaces. Since molten resin does not easily flow into such a minute gap, there is a risk that an air layer that provides high heat dissipation resistance is formed. Therefore, as shown in FIG. 8, by forming a convex shape on at least one surface of the core lower surface 121e and the block upper surface 122b, only a partial region of each surface is in close contact with the remaining region. Make sure the gap is positive. Since molten resin flows into the gap to form a resin layer, no air layer is formed between the core lower surface 121e and the block upper surface 122b. Therefore, the efficiency of heat transfer from the U core 121 to the metal block 122 is improved.

DESCRIPTION OF SYMBOLS 1 Coil apparatus 10 Ring core unit 12A, 12B Insert molding core 14 Gap member 16 I core 20 Coil 22, 24 Linear coil part 22a, 24a Lead part 26 Coil connection wire 30 Bus bar 40 Heat radiation sheet 121 U core 121a Core leg part 121b Core side surface 121c Core leg end surface 121d Core upper surface 121e Core lower surface 122 Metal block 122a Block lower surface 122b Block upper surface 123 Hollow cylinder part 123a Cylinder opening 123A Claw part 123B Claw fitting part 124, 125 Non-resin-covered area 126 Resin flange 127 Metal flange 127a Fixing hole 200 Insert molding die 202 Cavity bottom surface 204 First movable die 206 Cavity side wall surface 208 Second movable die 300 Inverter case

Claims (19)

A placing step of placing the core and a heat conduction block having a higher thermal conductivity than the resin in an insert mold for the core in a state where the core and the heat conduction block are stacked in the vertical direction;
By pressing the one side surface of the core and pressing the other side surface of the core against the side wall surface in the insert molding die by the first movable die movable in the left-right direction in the insert molding die, the insert molding die The position of the core in the mold is determined, and the upper surface of the core is pushed by a second movable mold that is movable in the vertical direction in the insert mold, so that the lower surface of the heat conduction block becomes the bottom surface in the insert mold. in Rukoto brought into close contact with pressure, and the opposing surface adhesion step of adhering the mutual opposed surfaces of the core and the heat conductive block,
An injection step of injecting a molten resin into the insert mold,
By curing the injected molten resin into the insert mold in a mold to obtain an insert molding core the core and the heat conduction block coated with resin is in a state in which the opposing surfaces of the each other in close contact directly,
The manufacturing method of the insert molding core for coil apparatuses containing this. Including a bus bar installation step of installing a bus bar to be connected to a coil terminal of a coil device on which the core is mounted on the insert mold,
The manufacturing method of the insert molding core for coil apparatuses of Claim 1 which obtains the insert molding core which has the bus-bar by which the root part was insert-molded in the said formation process. The heat conduction block has a flange portion in which a fixing hole for fixing the insert molding core to a predetermined cooler is formed,
During the facing surface contact step, the flange portion is fixed at a position where the molten resin does not flow,
The manufacturing method of the insert molding core for coil apparatuses of Claim 1 or Claim 2 which obtains the insert molding core which the said flange part exposed in the said formation process. In the facing surface contact step, at least one of the facing surfaces has a convex shape so that only a part of the facing surfaces of the core and the heat conduction block are in close contact with each other.
In the injection step, the molten resin is injected into the gap between the facing surfaces,
The manufacturing method of the insert molding core for coil apparatuses as described in any one of Claims 1-3 which obtains the insert molding core by which the clearance gap between the said opposing surfaces was filled with resin in the said formation process. The core is a substantially U-shaped U core having two legs arranged in parallel,
In the facing surface contact step, the leg end surfaces of the two legs are pressed against the side wall surface in the insert mold by the first movable mold,
The resin coating on the U core forms a substantially cylindrical hollow cylindrical portion by extending in a direction away from the U core beyond the leg end surface. The manufacturing method of the insert molding core for coil apparatuses as described in one term.   In the molding step, the side wall surface and the bottom surface in the insert mold perpendicular to each other are transferred, so that the bottom surface of the heat conduction block and the leg end surface of the U core are orthogonal to each other. The manufacturing method of the insert molding core for coil apparatuses of Claim 5 which obtains. A method for manufacturing a ring core unit for a coil device, wherein a ring core unit for a coil device is manufactured using a pair of insert molded cores manufactured by the method for manufacturing an insert molded core for a coil device according to claim 5 or 6. And
An interposed member inserting step of inserting a predetermined interposed member into the hollow cylindrical portion from the opening of the hollow cylindrical portion of each of the pair of insert molding cores;
A ring core unit forming step of forming a ring core unit by abutting the openings of the pair of insert molding cores into which the predetermined interposition member is inserted;
The manufacturing method of the ring core unit for coil apparatuses containing this. The predetermined interposition member is
A substantially rod-shaped I core constituting a magnetic path between the leg end faces of the pair of U cores;
A gap member disposed between each of the U core and the I core, the I cores;
The manufacturing method of the ring core unit for coil apparatuses of Claim 7 which has these. A coil device manufacturing method for manufacturing a coil device using a ring core unit manufactured by the method for manufacturing a ring core unit for a coil device according to claim 7 or 8,
The manufacturing method of a coil apparatus including the coil winding process which winds a coil on the outer periphery of the core internal part in which a core exists through the said resin coating among the said ring core units. The heat-dissipating sheet contact process which makes the heat-dissipating sheet which fills the level | step difference of the lower surface of the said heat conductive block which is a non-resin coating area | region, and the lower surface of the outer periphery of the said coil adhere on the lower surface of the outer periphery of this coil, The manufacturing method of the coil apparatus of description. The manufacturing method of the coil apparatus of Claim 9 or Claim 10 which includes the bus-bar connection process which connects the said coil terminal to the said bus-bar. An insert molding core resin-coated by insert molding;
A coil for winding the outer periphery of the insert-molded core from above the resin coating;
With
The insert molded core is
The core,
A heat conductive block having a higher thermal conductivity than the resin, in a state of being in direct contact with the core in the resin coating;
Have
A coil device, wherein a part of the heat conduction block is exposed on a lower surface of the insert molding core that is in surface contact with a predetermined cooler. The coil device according to claim 12, further comprising a bus bar fixed to at least one of the insert molding cores by insert molding and connected to a terminal of the coil. The heat conduction block has a flange portion that is a non-resin-coated portion,
The coil device according to claim 12 or 13, wherein a fixing hole for fixing the coil device to the predetermined cooler is formed in the flange portion. At least one of the facing surfaces of each other has a convex shape so that only a part of the facing surfaces of the core and the heat conduction block are in close contact with each other.
The coil device according to any one of claims 12 to 14, wherein a gap between the opposing surfaces is filled with a resin. A ring core unit comprising a pair of insert molded cores,
The pair of insert-molded cores are respectively
A substantially U-shaped U-core having two legs arranged in parallel;
The heat conducting block in close contact with the U core in the resin coating;
And the resin coating on the U core extends to the direction away from the U core beyond the leg end surfaces of the two legs, thereby forming a substantially cylindrical hollow cylinder. And
A predetermined interposition member is inserted into the hollow cylinder part from the opening of the hollow cylinder part,
16. The ring core unit according to claim 12, wherein the ring core unit is formed by abutting the openings of the pair of insert molding cores into which the predetermined interposition member is inserted. The coil device according to item.   The coil device according to claim 16, wherein the insert-molded core has a lower surface of the heat conducting block and a leg end surface of the U core orthogonal to each other. The predetermined interposition member is
A substantially rod-shaped I core constituting a magnetic path between the leg end faces of the pair of U cores;
A gap member disposed between each of the U core and the I core, the I cores;
The coil device according to claim 16 or 17, characterized by comprising:   The heat radiation sheet filling the step between the lower surface of the heat conduction block, which is a non-resin-covered region, and the lower surface of the outer periphery of the coil is in close contact with the lower surface of the outer periphery of the coil. The coil device according to any one of claims 18 to 18.

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