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Compact, method for producing compact, reactor, converter, and power conversion device

Inactive Publication Date: 2013-12-05
SUMITOMO ELECTRIC IND LTD +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention relates to a method for producing a compact, which can reduce eddy current loss and efficiently produce a low-miss compact. The resultant compact exhibits low eddy current loss, and the reactor used in the process also exhibits low loss. Thus, the technical effect of this invention is to improve the efficiency and performance of the compact.

Problems solved by technology

Thus, the insulating coatings of the coated soft magnetic particles may become damaged due to the pressure applied during the pressure-forming and sliding contact with the die at the time the compact is withdrawn from the die.
Damage on insulating coatings may cause exposure and stretching of the soft magnetic particles.
As a result, the soft magnetic particles in the compact may become conductive to each other and form film-shaped conductive portions and the eddy current loss may increase thereby.

Method used

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  • Compact, method for producing compact, reactor, converter, and power conversion device
  • Compact, method for producing compact, reactor, converter, and power conversion device
  • Compact, method for producing compact, reactor, converter, and power conversion device

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Effect test

first embodiment

Compact

[0078]A compact according to the present invention is obtained by pressure-forming coated soft magnetic powder that contains a plurality of coated soft magnetic particles each constituted by a soft magnetic particle having an outer periphery coated with an insulating coating and an iron-containing oxide film is present in at least part of a surface of the compact. The feature of the compact is that a particular amount of oxygen is contained in the surface portion where the oxide film is present. In the detailed description below, this feature is mainly described and the structure of the soft magnetic powder is described in the subsequent description of the production method. The constitutional elements of the compact substantially retain the characteristics and properties of ingredients.

[0079]An iron-containing oxide film is present in at least part of a surface of the compact. Assuming that the total content of iron and oxygen in the surface portion of the compact where the ...

second embodiment

Reactor

[0153]The compact described above and a compact produced by the above-described method for producing a compact are suitable for use in constitutional members of reactors. For example, a reactor includes a coil obtained by winding a wire, and a magnetic core that is arranged on the inner side and the outer side of the coil and forms a closed magnetic circuit. At least part of the magnetic core is constituted by a compact. This compact may be the compact of the present invention. In other words, the feature of the reactor of the present invention is that the compact described above is used in at least part of the magnetic core of the reactor. An example of the reactor is described below with reference to FIGS. 1 and 2. The description is provided by using an example in which the compacts of the present invention are used in inner core units 31 of a magnetic core 3 of a reactor 100, the inner core units 31 being arranged on the inner side of a coil 2. Known structures of reactor...

third embodiment

Converter and Power Conversion Device

[0164]The reactor described above can be used as a constitutional part of a converter mounted in vehicles, for example, and a constitutional part of a power conversion device that includes the converter.

[0165]For example, as shown in FIG. 3, a vehicle 1200 such as a hybrid car or an electric car includes a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and a motor (load) 1220 driven by power supplied from the main battery 1210 and used for driving. The motor 1220 is typically a three-phase AC motor, drives wheels 1250 during driving, and functions as a power generator during regeneration. When the vehicle 1200 is a hybrid car, an engine is provided in addition to the motor 1220. In FIG. 3, an inlet is illustrated as a portion of the vehicle 1200 at which charging is conducted. Alternatively, the vehicle 1200 may be equipped with a plug.

[0166]The power conversion device 1100 includes a converter 1110 connecte...

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Abstract

A low-loss compact and a method for producing the compact are provided.A method for producing a compact by using coated soft magnetic powder that includes coated soft magnetic particles constituted by soft magnetic particles and insulating coatings coating outer peripheries of the soft magnetic particles includes a raw material preparation step and an irradiation step. In the raw material preparation step, a raw compact is prepared by press-forming coated soft magnetic powder. In the irradiation step, part of a surface of the raw compact is irradiated with a laser. Irradiating a part of a surface of a raw compact with laser increases the number of disrupted portions of conductive portions where constituent materials of the soft magnetic particles at the surface of the raw compact have become conductive to each other, and the loss of the compact can be decreased.

Description

TECHNICAL FIELD[0001]The present invention relates to a compact obtained by pressure-forming coated soft magnetic powder, a method for producing the compact, a reactor that includes the compact, a converter that includes the reactor, and a power conversion device that includes the converter. In particular, the present invention relates to a low-loss compact and a method for producing the low-loss compact.BACKGROUND ART[0002]Systems that supply power to motors in hybrid cars etc., are equipped with boosting circuits. Reactors are used as one component of the boosting circuits. Reactors are configured by winding a coil on a core. In the case where a core is used under an alternating magnetic field, a loss called iron loss occurs in the core. Iron loss is roughly expressed as a sum of a hysteresis loss and an eddy-current loss and is particularly high when the core is used at high frequencies.[0003]In order to decrease the iron loss in a reactor core, a core formed of a compact is some...

Claims

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Application Information

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IPC IPC(8): H01F3/08B23K26/00H02M7/44H01F41/02B22F1/102B22F1/16
CPCH01F3/08H01F41/0246B23K26/0081H02M7/44H01F37/00H01F1/33B22F2998/10B22F2999/00C22C2202/02Y10T29/4902B23K26/354H01F1/24B22F1/16B22F1/102B22F3/24B22F2202/11B22F3/02H01F41/02B22F3/105B22F3/12
Inventor KUSAWAKE, KAZUSHIUOZUMI, MASATOSATO, ATSUSHIYAMAGUCHI, KOJIONO, MAMORUMURASE, HIROYUKINAKAMAE, KAZUO
Owner SUMITOMO ELECTRIC IND LTD
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