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

[0060]A method for producing a compact according to the present invention can reduce the eddy current loss and can efficiently produce a low-los compact.
[0061]A compac

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due to the pressure applied during the pressure-forming and sliding contact with the die at the time the compact is withdrawn from the die.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 coa

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

Examples

Experimental program
Comparison scheme
Effect test

Example

Test Example 1

[0169]In Test Example 1, compacts of samples 1-1 to 1-3 were prepared as below and the magnetic properties of the samples were tested as described below.

[0170][Sample 1-1]

[0171]A compact of Sample 1-1 is prepared through the steps described below in the order of step a→step b→step c→step d.

[0172]Step a: Ingredient preparation step of preparing coated soft magnetic powder

[0173]Step b: Raw material forming step of pressure-forming the coated soft magnetic powder to prepare a raw compact

[0174]Step c: Heat treatment step of heating the raw compact to form a heat-treated compact

[0175]Step d: Irradiation step of irradiating a surface of the heat-treated compact with a laser.

[0176](Step a)

[0177]A mixture material containing coated soft magnetic powder obtained by coating surfaces of soft magnetic particles composed of iron powder with insulating coatings composed of iron phosphate, and 0.6 mass % of a lubricant composed of zinc stearate was prepared as a constituent material ...

Example

Test Example 2

[0205]In Test Example 2, Samples 2-1 and 2-2 were prepared by the same orders of the steps as with Samples 1-1 and 1-2 in Test Example 1 but under different laser irradiation conditions in step d. The magnetic properties of these samples were evaluated as in Evaluation 1 above. The laser irradiation conditions are described below and the observed characteristic values are shown in Table 2. In the table, the results of Sample 1-3 prepared in Test Example 1 are also shown.

[0206]

[0207]Type: fiber laser

[0208]Wavelength: 1064 nm

[0209]Irradiation interval / beam diameter ratio: 0.07

[0210]Pulse width: 120 ns

[0211]Scan interval / beam diameter ratio: 0.05

[0212]Number of times of overlap: 40

[0213]Energy density U: 123.6 W / mm2

TABLE 2SampleEddy currentHysteresisLoss WNo.loss We (W)loss Wh (W)(W)2-11.116.517.62-21.416.618.01-317.517.434.9

[0214]>

[0215]As in Test Example 1, Samples 2-1 and 2-2 having surfaces partly irradiated with a laser showed lower eddy current losses compared to Sa...

Example

Test Example 3

[0216]In Test Example 3, Samples 3-1 to 3-10 were prepared under the same conditions as with Sample 2-1 prepared in Test Example 2 except that the energy density U among the laser irradiation conditions in step d was changed. The magnetic properties of the samples were evaluated as in Evaluation 1 above. The energy density U applied to each sample and the observed characteristic values are shown in Table 3 and FIG. 5.

TABLE 3EnergySampledensity UEddy currentHysteresisLoss WNo.(W / mm2)loss We (W)loss Wh (W)(W)3-125.415.418.133.53-231.310.317.627.93-339.14.716.821.53-450.12.016.818.83-588.11.016.517.53-6123.61.016.617.63-7182.61.016.717.73-8290.81.316.317.63-9442.74.616.921.5 3-10518.911.317.628.9

[0217]>

[0218]Compared to Sample 1-3 (Test Example 1), all of Samples 3-1 to 3-10 exhibited a lower eddy current loss. The eddy current loss was lower in Samples 3-3 to 3-9 than in Samples 3-1, 3-2, and 3-10. In particular, Samples 3-4 to 3-8 exhibited particularly low eddy current...

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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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