Core component for a power detector, power detector, power conversion device and method for manufacturing a core component for a power detector

Abstract

A core component for a current detector comprises a ring-shaped core with a slit section designed as a cut, and a first forming section that seals the core in such a way that it partially covers core end faces, which are a pair of end faces of the core facing the slit section.

Description

Technical field

[0001] The present invention relates to a core component for a current detector, a current detector, a power conversion device and a method for manufacturing a core component for a current detector. State of the art

[0002] A configuration of PTL 1 is known as a core component for a current detector. PTL 1 discloses a current sensor comprising: a magnetic core surrounding a busbar through which a measuring current flows and having a gap along a path surrounding the busbar; a detection element arranged in the gap such that a detection direction runs along an interval direction of the gap and detects the strength of a magnetic field; a first resin covering an outer circumferential surface of the core; and a second resin provided between the outer circumferential surface of the busbar and an inner circumferential surface of the core to cover the outer circumferential surface of the first resin, and having a linear expansion coefficient that is smaller than the linear expansion coefficient of the first resin. List of literature on patent literature

[0003] PTL 1: JP 2013-185875 A Summary of the invention: Technical problem

[0004] With regard to the invention described in PTL 1, there is still room for improvements concerning the accuracy of the gap distance. Solution to the problem

[0005] A core component for a current detector according to a first aspect of the present invention comprises: an annular core with a slit section formed as a cut; and a first shaped section sealing the core in such a way that it partially covers core end faces which are a pair of end faces of the core facing the slit section.

[0006] A current detector according to a second aspect of the present invention further comprises: the core component for a current detector described above; and a magnetic detection element arranged in the gap section.

[0007] Furthermore, a power conversion device according to a third aspect of the present invention comprises: the current detector described above; a busbar penetrating an inner circumferential side of the core; and a power conversion circuit connected to the busbar.

[0008] A method for manufacturing a core component for a current detector according to a fourth aspect of the present invention further comprises a method for manufacturing a core component for a current detector, the method comprising: a step of forming a slit section which is designed as a cut in a part of an annular core; a step of arranging the core in a primary mold in which a primary bearing surface is formed, which is a bearing surface which abuts a part of a core end face which is a pair of end faces of the core which are facing the slit section; and a step of injecting a resin material into the primary mold and forming a first mold section which covers at least one covering area which is a region of the end face except for the one section. Advantageous effects of the invention

[0009] According to the present invention, the accuracy of the gap spacing in the core component can be ensured. Brief description of the drawings [ Fig. 1] Fig. Figure 1 is a configuration diagram of an inverter containing a core component. [ Fig. 2] Fig. Figure 2 is a schematic configuration diagram of a current sensor. [ Fig. 3] Fig. Figure 3 is a perspective view of the current sensor. [ Fig. 4] Fig. Figure 4 is a view illustrating details of the core component. [ Fig. 5] Fig. Figure 5 is a view illustrating details of the core component. [ Fig. 6] Fig. Figure 6 is a view to explain a manufacturing step of the core component. [ Fig. 7] Fig. Figure 7 is an external view of a current sensor and a core component in a first modification. [ Fig. 8] Fig. Figure 8 is a view to explain a manufacturing step of a core component in a second modification. [ Fig. 9] Fig. Figure 9 is a view illustrating details of a core component in a second embodiment. Description of the embodiments-First embodiment-

[0010] A first embodiment of a core component for a current detector according to the present invention is described below with reference to the Fig. 1 to Fig. 6 described.

[0011] Fig. Figure 1 shows a configuration diagram of an inverter 1, which includes a core component that will be described in detail later. Here, the inverter 1 is designed as a power conversion device mounted on an electric vehicle or the like. The inverter 1 is also connected to a battery 2, a vehicle system 3, and a motor 4. The battery 2 supplies the inverter 1 with single-phase power. The vehicle system 3 also outputs a control signal to the inverter 1. The motor 4 is driven by three-phase alternating current, which is supplied by the inverter 1 via a busbar 41. However, the motor 4 can also supply the inverter 1 with three-phase alternating current power, and the inverter 1 can convert the three-phase alternating current power into a single phase and supply the battery 2 with the single-phase alternating current power.The inverter 1 also contains a current sensor 11, a power module 12, a capacitor 13 and a control unit 14.

[0012] Inverter 1 controls the torque and speed of motor 4 based on a control command received from the vehicle system 3. Control is achieved using three-phase current detection, motor angle detection, and input voltage to ensure optimal control within the control range and optimal efficiency. Current sensor 11 is used to detect the current flowing through busbar 41. Current sensor 11 is essential for controlling motor 4 because improved accuracy and durability of current detection lead to improved vehicle performance and lifespan.

[0013] Fig. Figure 2 shows a schematic configuration diagram of the current sensor 11. The upper part of Fig. Figure 2 shows a top view of the current sensor 11, the middle part of Fig. 2 a front view of the current sensor 11 and the lower part of Fig. Figure 2 shows a front view of the current sensor 11, excluding a housing 114 and the like, which are described later. The current sensor 11 comprises a substrate 111, a magnetic detection element 112, a housing 114, a positioning pin 115, a metal bushing 116, a pin head 117, and a core component 118. The current sensor 11 is also firmly attached to the housing of the inverter 1 by the positioning pin 115 and the metal bushing 116. Furthermore, a busbar 41 for each UVW phase penetrates the interior of the current sensor 11.

[0014] As in the middle part of Fig. As illustrated in Figure 2, each busbar 41 is surrounded by the core component 118. The magnetic detection element 112 is located inside the housing 114 in the front view, and the core 1181 is located inside the core component 118. As described later, the core component 118 further comprises a core 1181 and a molded section 1182. The molded section 1182 will also be described in detail later.

[0015] The lower part of Fig. Figure 2 is a front view of the current sensor 11, excluding the housing 114 and the molded section 1182 of the core component 118. A region H in the lower part of Fig. 2 also represents an area covered by the housing 114. The core 1181, which forms the core component 118, furthermore has a ring shape with a cut, and this cut section is hereinafter also referred to as a gap section 1183. The magnetic detection element 112 is further arranged in the gap section 1183. A magnetic field is generated when the busbar 41 is energized, and a magnetic flux flows through the core 1181. The magnetic detection element 112, which is arranged in the gap section 1183, detects the magnetic flux flowing through the core 1181. Furthermore, the magnetic detection element 112 transmits the magnitude of the detected magnetic flux to the controller 14 via the substrate 111 and the pin head 117. As will be described later, the controller 14 can calculate the current based on the magnitude of the magnetic flux, since there is a correspondence relationship between the current and the magnetic flux.

[0016] Fig. Figure 3 is a perspective view of current sensor 11. The upper part of Fig. Figure 3 shows a perspective view with busbar 41, and the lower part of Fig. Figure 3 shows a perspective view without the busbar 41.

[0017] Fig. 4 and Fig. Figure 5 shows views illustrating details of the core component 118. The upper part of Fig. Figure 4 shows a perspective view of the core component 118, and the middle and lower parts of Fig. Figure 4 shows enlarged views of the area surrounding cleavage section 1183. Fig. 4 and Fig. Figure 5 also shows mutually orthogonal XYZ axes to clearly illustrate the correlation between the drawings. A large number of inner circumferential grooves 118V are provided in the inner circumferential section of the ring-shaped core component 118. More precisely, in Fig. 4 six inner circumferential grooves 118V are provided. The mold section 1182 is cut out in the inner circumferential groove 118V, and the core 1181 is exposed.

[0018] The greater part of the circumference of the core 1181 is further covered by the shaped section 1182. As described above, the annular core 1181 has a cut, and this cut section is hereinafter also referred to as the slit section 1183. A boundary between the end of the core 1181 and the slit section 1183 is also referred to as a core end surface 118E. A pair of core end surfaces 118E is located at two positions, with the slit section 1183 positioned between them. An enlarged view of the core end surface 118E is also shown in the middle and lower parts of Fig. Figure 4 illustrates this. The core 1181 of the molded section 1182 lies exposed on the core end surface 118E. This configuration is described in detail.

[0019] In the core end face 118E, a predetermined area on the inner diameter side, i.e., the negative Z-axis side, is designated as an inner diameter area 118N, and an area on the outer forming side, i.e., the positive Z-axis side with respect to the inner diameter area 118N, is hereinafter also referred to as an outer diameter area 118T. The inner diameter area 118N is covered by the forming section 1182, and the outer diameter area 118T is free of the forming section 1182. Since the inner diameter area 118N is covered by the forming section 1182, this area is hereinafter also referred to as a "covered area". A sub-area of ​​the outer circumferential surface of the core 1181, which is related to the outer diameter area 118T, is hereinafter also referred to as an exposed outer circumferential area 118G, and the exposed outer circumferential area 118G is free from the mold section 1182.Although only one of the pair of core end faces 118E is located in the middle part of . Fig. As illustrated in Figure 4, the pair of kernel end faces 118E also has a symmetrical shape, as shown in the lower part of Figure 4. Fig. 4 illustrates.

[0020] Fig. Figure 5 is a view illustrating the influence of the distance of the gap section 1183 on the current measurement. The upper part of Fig. Figure 5 illustrates the definition of a gap distance L. When a current flows through the busbar 41, a magnetic flux Φ is generated, as indicated by an arrow. Although the magnetic detection element 112, which detects the magnetic flux Φ, is located in Fig. 5. For the sake of simplicity of the graphic representation, the magnetic detection element 112 is arranged in the slit section 1183, as shown in Figure 5. Fig. Figure 2 illustrates the length of the slit section 1183, i.e., the distance at the cut section of the core 1181, is further defined as the slit spacing L.

[0021] The lower part of Fig. Figure 5 shows a graph illustrating the relationship between the current and the magnetic flux density, with the difference in the gap distance of the slit section 1183 plotted as a line. Since the relationship between the current flowing through the busbar 41 and the magnetic flux density is proportional until the core 1181 is saturated, the relationship is preset to be equal to or less than the saturation point. Under this assumption, the current flowing through the busbar 41 can be calculated accordingly based on the magnetic flux detected by the magnetic detection element 112. The saturation and magnetic properties of the core 1181 are influenced by the external environment (temperature) and the material, the cross-sectional area of ​​the core 1181, the magnetic path of the core 1181, and the like, but also strongly by the variation in the gap distance L.The magnetic resistance of the gap section 1183 has a significant influence on the magnetic flux Φ, since the permeability of air is low. More precisely, the permeability of the air present in the gap section 1183 is very low, amounting to less than a few thousandths of the permeability of the core 1181. Furthermore, the magnetic resistance R, the gap spacing L, the magnetic permeability µ, and the effective cross-sectional area A in the gap section 1183 exhibit the following relationships. R=L / (μ×A)

[0022] This means that if the gap distance L is divided by the product of the magnetic permeability µ and the effective cross-sectional area A, the magnetic resistance R is obtained. Consequently, if the gap distance L varies, the variation in magnetic resistance R, the variation in magnetic flux Φ, the variation in magnetic flux density, and the variation in current are all related. (Manufacturing step)

[0023] Fig. Figure 6 is a view illustrating a manufacturing step of the core component 118. The core component 118 comprises a core formation step, a primary forming step, and a secondary forming step. First, in the core formation step, the electromagnetic steel sheet is bent or laminated to form the core 1181 with a predetermined gap. The forming section 1182 is then formed around the core 1181 by performing the primary and secondary forming operations, described below, using the core 1181. The forming section 1182 is designed for the purpose of accurately positioning the magnetic detection element 112 at a predetermined position on the inverter 1, improving the positional accuracy, strength, and durability of each component, and the like.

[0024] In Fig. Figure 6 shows a hatching of diagonal lines representing core 1181, and a hatching of dots representing the shape tool. The upper part of Fig. Figure 6 illustrates the primary molding step. In the primary molding step, the core 1181 is positioned within a primary mold 71, and the resin is filled, for example, from a lower gate opening G1. The tip sections of the arrows M1 to M10, which are located in the upper part of Fig. Figure 6 illustrates these as pressure surfaces where the primary forming tool 71 and the core 1181 are in contact. Below this, M1 to M6 correspond to the inner circumferential grooves 118V, which, with reference to the upper part of Fig. 4 are described. In particular, the inner circumferential grooves 118V at positions M1 and M6 expose the inner circumferential surface of the core 1181, which is connected to the core end surface 118E. Hereinafter, the surface of the core 1181 exposed in the inner circumferential groove 118V is also referred to as an "exposed section". Furthermore, at M8 and M9, the outer diameter region 118T of the core end surface 118E and the primary forming tool 71 are in direct contact with each other. The surfaces specified by M8 and M9 in the primary forming tool 71 are hereafter also referred to as "primary contact surfaces".

[0025] A reference surface of the core 1181 is defined such that a dimensional standard is established at the time of primary molding, and positioning is achieved by resin injection pressure or by applying pressure to an exposed section to improve dimensional accuracy. For this purpose, a spring structure may be provided within the primary mold 71 to exert pressure on the reference surface. The reference surface is the surface of the core 1181 that is in contact with the primary mold 71. The reference surface may be, for example, an upper section of the inner circumference, indicated by the reference numeral K, a lower section of the inner circumference, or a lateral direction in the drawing. For example, the core 1181, focused on M3 and M4, is exposed in the direction of the inner circumferential side of the core 1181 and the side opposite gate G1.It is desirable that the exposed section on the opposite side of core 1181 of the pressurizing part be used as a reference surface. As in the upper part of . Fig. As shown in Figure 6, in a case where the resin is filled from gate G1 of the lower diagram, it is desirable to use M3 and M4, which are exposed sections on the opposite side of core 1181, as reference surfaces. In the configuration of Fig. 6. Gate G1 is also formed on one side opposite gap section 1183.

[0026] Although gate G1 is shown in the lower part of this drawing, it can also be located near the gap section 1183 in the upper part of the drawing. In the primary forming step, the first forming section 1182A is formed between the primary forming tool 71 and the core 1181. The first forming section 1182A covers the entire outer circumference of the core 1181. In this drawing, the first forming section 1182A covers the outer circumference of the core 1181 without a gap, although a gap may also be provided in the outer circumference to prevent deformation or the like. Furthermore, the area covered by the housing 114 can also be exposed by the first forming section 1182A if this area is the outer circumference section of the core 1181.

[0027] This means that the primary forming step comprises steps 1-1 and 1-2, described below. Step 1-1 is a step of arranging the core 1181 in the primary mold 71, in which the bearing surface is formed that abuts the outer diameter region 118T, which is part of the core end face 118E. Step 1-2 is a step of injecting a resin material into the primary mold 71 to form the first mold section 1182A, which covers the inner diameter region 118N, which is part of the core end face 118E, excluding the outer diameter region 118T. By forming the first mold section 1182A through the primary molding step and covering the entire outer circumference of the core 1181, reliability, such as corrosion resistance, is improved, and defects in availability and appearance, such as rust during manufacturing or after a durability test, are reduced.

[0028] The secondary mold 72, used in the secondary molding step, is divided into an upper mold 721 and a lower mold 722. In the secondary molding step, the circumference of the core 1181, which is covered by the first mold section 1182A formed in the primary molding step, is surrounded by the upper mold 721 and the lower mold 722, and the gap of the secondary mold 72 is filled with resin to form the second mold section 1182B. The second mold section 1182B covers the outer diameter region 118T, which is located in the middle part of Fig. 4 is illustrated, and the exposed outer circumference area 118G, which is located in the lower part of Fig. Figure 4 illustrates areas exposed by the first shaped section 1182A in the vicinity of the core end surface 118E.

[0029] In the lower part of Fig. 6 is the second shaped section 1182B, shown in white, and is located to the right, left and center and between the pair of core end faces 118E and the slit section 1183. Fig. However, while Figure 6 illustrates a cross-section of the core component 118, the cross-section is only illustrated while it is divided into 5 sections, and the cross-section is actually connected to one of these sections. That is, since part of the second shaped section 1182B connects the core end faces 118E, this area can henceforth also be referred to as a 'connecting section'. Furthermore, the lower right and lower left areas of the first shaped section 1182A, designated by the reference numeral V, represent empty areas.

[0030] A tip section of each arrow, which is located in the lower part of Fig. Figure 6 further illustrates a contact surface where the secondary forming tool 72 and the first forming section 1182A come into contact. Specifically, the secondary forming tool 72 rests against the surface of the first forming section 1182A at the positions indicated by arrows N1 and N2. This surface covers the inner diameter area 118N, which is hereinafter also referred to as a covered area. The surfaces indicated by N1 and N2 in the secondary forming tool 72 are hereinafter also referred to as "secondary contact surfaces".

[0031] In the secondary forming step, the secondary forming is also carried out with reference to one of the reference surfaces, thus improving the dimensional accuracy of the finished product. However, the reference surface in the secondary forming step is any surface of the first forming section 1182A. The upper forming tool 721 has a secondary contact surface for this purpose, which is a contact surface that abuts the surface of the first forming section 1182A covering the inner diameter area 118N.

[0032] This means that the secondary forming step comprises steps 2-1 and 2-2 described below. Step 2-1 involves arranging the core 1181, in which the first forming section 1182A is formed, in the secondary forming tool 72, where the contact surface is formed that abuts the surface of the first forming section 1182A, covering the inner diameter region 118N, also referred to as the covered region. Step 2-2 further involves injecting a resin material into the secondary forming tool 72 to form the second forming section 1182B, which covers at least the outer diameter region 118T in the core end face 118E.

[0033] Since the gap section 1183 has a high magnetic resistance, it is easily influenced by magnetic properties, as described above. Part of the exposed gap section 1183 is pressed, and the primary forming is carried out. The pressing surface of the first forming section is then pressed directly in the secondary forming step. Consequently, because the variation in the gap distance L is reduced and the positioning effect is achieved as described above, the variation in magnetic flux can be managed by pressing, ensuring dimensional accuracy. Some resin may escape from the pressing surface and the contact surface due to dimensional variations and forming pressure, and a thin wall may remain on the pressing surface and the contact surface. However, this does not affect the positioning effect of the direct pressing.Furthermore, although this can only be completed by primary forming, there is the advantage that the magnetic saturation is set and the magnetic properties are stabilized in the primary forming process, so that by secondary use (it is easy to apply the core alone, including the corrosion resistance, to a different specification), the shape can be easily formed by secondary forming (reducing the amount of material to be used), and the dimensional accuracy of the positioning section can be easily achieved.

[0034] According to the first embodiment described above, the following operational effects can be achieved. (1) The core component 118 for the current sensor 11 comprises the annular core 1181 with the gap section 1183, which is configured as a cut, and the first forming section 1182A, which seals the core 1181 in such a way that it partially covers core end faces 118E, which are a pair of end faces of the core 1181 facing the gap section 1183. Because the core component 118 has such a configuration, the accuracy of the gap distance L can be ensured at the time of forming the core component 118. (2) The first mold section 1182A covers the entire outer circumference of the core 1181. Furthermore, the first mold section 1182A is formed from a single component. Therefore, the reliability, such as corrosion resistance, of the core 1181 is improved, and a mold covering the entire outer circumference can be formed. (3) The inner diameter region 118N on the inner diameter side of the core end face 118E is covered by the first forming section 1182A. Furthermore, the outer diameter region 118T, which is a region on the outer diameter side of the inner diameter region 118N in the core end face 118E, and the exposed outer circumferential region 118G, which is a part of the outer circumferential surface of the core 1181 that is related to the outer diameter region 118T, are free from the first forming section 1182A. Therefore, the core end face 118E can be supported by two surfaces at the time of forming the core component 118, and its formability can be stabilized. (4) In the first mold section 1182A, an exposed section is formed in which the core 1181 is exposed towards the side opposite gate G1, into which the resin material is injected at the time of molding the first mold section 1182A. Therefore, the pressure of the resin injection and the like is applied, and the core 1181 is pressed against the exposed surface of the core 1181 on the opposite side of gate G1, and the dimensional accuracy is stabilized; (5) The core component 118 comprises the second mold section 1182B, which seals the core 1181 and the first mold section 1182A in such a way that it covers an area of ​​the core end face 118E that is not covered by the first mold section 1182A. Therefore, the layout of the first mold section 1182A and the core 1181 is improved. In addition, by sealing an uncovered section of the first mold section 1182A, dimensional accuracy is improved, and magnetic properties and durability reliability are also enhanced. (6) The second mold section 1182B has a connecting section that joins the core end faces 118E. This prevents the gap distance L from varying after manufacturing. (7) The current sensor 11, which is a current detector, comprises the core component 118 described above and the magnetic detection element 112, which is arranged in the gap section 1183. (8) The inverter 1 comprises a busbar 41 penetrating the inner circumferential side of the core 1181 and the substrate 111 comprising a power conversion circuit connected to the busbar 41. (9) The method for manufacturing the core component 118 comprises the core formation step and the primary forming step. The core formation step is a step in forming the gap section 1183, which is formed as a cut in a part of the annular core 1181. The primary forming step further comprises a step 1-1 and a step 1-2. Step 1-1 is a step in arranging the core 1181 in the primary forming tool 71, in which primary contact surfaces (surfaces specified by M8 and M9 in the primary forming tool 71) are formed. These contact surfaces are in contact with a part of the core end surface 118E, which is a pair of end surfaces of the core 1181 facing the gap section 1183.Step 1-2 involves injecting a resin material into the primary mold 71 to form the first mold section 1182A, which covers at least the inner diameter region 118N, a region of the end face excluding the outer diameter region 118T. Therefore, the accuracy of the gap distance L can be ensured by bringing the outer diameter region 118T into direct contact with the primary mold 71 at the time of primary forming. (10) The secondary forming step, which is a method for producing the core component 118 and is carried out after the primary forming step, further comprises a step 2-1 and a step 2-2. Step 2-1 is a step of arranging the core 1181, in which the first forming section 1182A is formed, in the secondary forming tool 72, in which the contact surface is formed that bears against the surface of the first forming section 1182A, covering the inner diameter region 118N, also referred to as the covered region. Step 2-2 is further a step of injecting a resin material into the secondary forming tool 72 to form the second forming section 1182B, which covers at least the outer diameter region 118T in the core end face 118E.Therefore, the accuracy of the gap distance L can be ensured by bringing the secondary forming tool 72 into alignment with the first forming section 1182A, which is formed in the primary forming step in the secondary forming step. (First modification)

[0035] In the embodiment described above, the entire core 1181 is covered by the molded section 1182. However, it is also possible for only a part of the core 1181 to be covered by the molded section 1182.

[0036] Fig. Figure 7 is an external view of the current sensor 11 and the core component 118 according to a first modification. The upper part of Fig. 7 corresponds to the lower part of Fig. 3 in the first embodiment, and the lower part of Fig. 7 corresponds to the upper part of Fig. 4 in the first embodiment. In the present modification, the configuration of the core end surface 118E is also similar to that of the first embodiment, and differs in that the lower half of the core 1181 in the drawing is not covered by the mold section 1182.

[0037] Furthermore, the first mold section 1182A is divided into two parts in the present modification. Therefore, when forming the first mold section 1182A, it is necessary to provide gates to be filled with resin on the upper part in the drawing, for example near the gap section 1183. (Second modification)

[0038] Fig. Figure 8 is a view to explain a manufacturing step of the core component 118 according to a second modification. Fig. 8 corresponds to the upper part of Fig. 6. The difference to Fig. 6 consists of the position of the gate and the position of the pressing surface. Fig. In the drawing, gate G1 is located at the lower part, whereas in the present modification, gates G2 and G3 are located at two positions in the upper part. Furthermore, in the present modification, there is no pressing surface at positions M3 and M4. Fig. 6. Furthermore, in the present modification, the inner circumferential grooves 118V are also provided similarly to the first embodiment. Similar to the first embodiment, the inner circumferential grooves 118V, in particular at positions M1 and M6, expose the inner circumferential surface of the core 1181, which is connected to the core end surface 118E.

[0039] According to the present modification, the following operational effects can therefore be achieved.

[0040] (11) Gate G2 and gate G3 are provided on the outer circumferential surface of core 1181 on the side where the gap section 1183 is formed. Furthermore, the inner circumferential surface of core 1181, which is connected to the core end surface 118E, is exposed in the inner circumferential grooves 118V of M1 and M6 on the exposed section. Therefore, the pressure of the resin injection and the like is applied, and core 1181 is pressed against the exposed surface of core 1181 on the opposite side of gate G1, thus stabilizing the dimensional accuracy. In addition, partial forming of core 1181 can be easily carried out, miniaturization and material savings can be achieved. (Third modification)

[0041] In the first embodiment described above, the mold section 1182 comprises the first mold section 1182A and the second mold section 1182B. However, the mold section 1182 can also comprise only the first mold section 1182A. In other words, the mold section 1182 can also not comprise the second mold section 1182B.

[0042] Furthermore, when forming the mold section 1182, approximately the same shape can be formed at one time instead of the two-stage forming process, as in Fig. Figure 6 illustrates this. In this case, although the forming tool is more complicated than in the first embodiment, the advantage is that the forming process is only carried out once. -Second embodiment-

[0043] A second embodiment of the core component is further described with reference to Fig. 9. In the following description, the same components as those of the first embodiment are designated with the same reference numerals, and the main differences are described. The points not specifically described are also the same as those in the first embodiment. The present embodiment differs from the first embodiment mainly in the configuration of the core end face.

[0044] Fig. Figure 9 shows a view illustrating details of the core component 118A in the second embodiment. The upper part of Fig. Figure 9 shows a perspective view of the core component 118A, the central part of Fig. 9 an enlarged view of the core end face 118E and the lower part of Fig. Figure 9 shows a front view of the core component 118A. Fig. Furthermore, orthogonal XYZ axes are illustrated in Figure 9 to clearly demonstrate the correlation between the drawings. As shown in the lower part of Fig. As illustrated in Figure 9, the approximate center of kernel 1181, with its approximately ring-shaped form, is designated as a virtual axis J. The virtual axis J is parallel to the Y-axis.

[0045] The core 1181 has a thickness in the direction of the virtual axis J. Furthermore, in the core end face 118E, as in the middle part of Fig. Figure 9 illustrates a central section in the direction of the Y-axis, that is, the virtual axis J, designated as an end-surface central section 118EC. The end-surface central section 118EC is also covered by the first shaped section 1182A. The core 1181 is free from the first shaped section 1182A on both sides of the virtual axis J in order to enclose the end-surface central section 118EC. Furthermore, in the central part of Fig. Figure 9 merely illustrates the kernel end surface 118E on the negative side of the X-axis for the sake of simplicity of the graphic representation, however, the kernel end surface 118E on the positive side of the X-axis has a similar configuration.

[0046] According to the second embodiment described above, the following operational effects can be achieved.

[0047] (12) The core 1181 has an annular shape, approximately centered on the virtual axis J parallel to the Y-axis. The core 1181 has a thickness in the direction of the virtual axis J. The end-face center section 118EC, which is a center section of the core end face 118E in the direction of the virtual axis J, is also covered by the first forming section 1182A. Above this, the end faces on both sides in the Y-axis direction, which enclose the end-face center section 118EC, are free of the first forming section 1182A. Therefore, since the end-face center section 118EC of the core component 118 is covered by the first forming section 1182A, the insertion and removal performance of the forming tool in the gap section 1183 is improved when the second forming section 1182B is formed, and the formability (productivity) is improved.

[0048] The embodiments and modifications described above can be combined. Although various embodiments and modifications have been described above, the present invention is not limited to these. Other aspects conceivable within the scope of the technical idea of ​​the present invention are also included within its scope. Reference symbol list 1 inverter 41 Busbar 71 primary forming tool 72 secondary forming tool 111 Substrat 112 magnetic detection element 118 Core component 118E Core end surface 118G exposed outer circumference 118N inner diameter range 118T outer diameter range 118V inner circumferential groove 721 upper forming tool 722 lower forming tool 1181 core 1182 Section 1182A first mold section 1182B second form section 1183 Split section QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] JP 2013-185875 A

[0003]

Claims

[1] A core component for a current detector, comprising: a ring-shaped core with a slit section formed as a cut; and a first forming section that seals the core in such a way that it partially covers core end faces, which are a pair of end faces of the core facing the slit section. [2] The core component for a current detector according to claim 1, wherein the first mold section further covers an outer circumference of the core over its entire circumference, and the first mold section is formed from a single component. [3] The core component for a current detector according to claim 1, wherein the core has a ring-shaped form that is approximately centered on a virtual axis, and the core has a thickness in one direction of the virtual axis, a central end-surface section, which is a central section in the direction of the virtual axis in the core end-surface, is covered with the first shaping section, and the end surfaces on both sides in the direction of the virtual axis enclosing the end surface middle section are exposed from the first shaping section. [4] The core component for a current detector according to claim 1, wherein an inner diameter area on an inner diameter side of the core end surface is covered with the first forming section, and an outer diameter region, which is a region on an outer diameter side of the inner diameter region in the core end face, and a partial region of an outer circumferential surface of the core, which is related to the outer diameter region, are exposed from the first forming section. [5] The core component for a current detector according to claim 1, wherein the first mold section is formed with an exposed section in which the core is exposed in the direction of one side opposite a gate into which a resin material is injected during the molding of the first mold section. [6] The core component for a current detector according to claim 5, wherein the gate is provided on one side of an outer circumferential surface of the core, on which the gap section is formed, and The exposed section reveals an inner circumferential surface of the nucleus that is related to the nucleus end surface. [7] The core component for a current detector according to claim 1, further comprising a second molded section which seals the core and the first molded section in such a way that it covers an area of ​​the core end face which is not covered by the first molded section. [8] The core component for a current detector according to claim 7, wherein the second molded section comprises a connecting section that connects the core end faces. [9] A current detector, comprising: a core component for a current detector according to claim 7; and a magnetic detection element that is arranged in the gap section. [10] A power conversion device comprising: the current detector according to claim 9; a busbar that penetrates an inner circumferential side of the core; and a power conversion circuit that is connected to the busbar. [11] A method for manufacturing a core component for a current detector, the method comprising: a step in the formation of a slit section, which is formed as a cut in a part of an annular core; a step of arranging the core in a primary forming tool in which a primary bearing surface is formed, which is a bearing surface that abuts a portion of a core end face, which is a pair of end faces of the core that face the slot section; and a step of injecting a resin material into the primary mold tool and forming a first mold section that covers at least one covering area, which is a region of the end surface except for the one section. [12] The method for manufacturing a core component for a current detector according to claim 11, further comprising a step of arranging the core, in which the first mold section is formed, in a secondary mold tool in which a secondary bearing surface is formed, which is a bearing surface that abuts a surface of the first mold section that covers the covering area; and a step of injecting a resin material into the secondary mold to form a second mold section that covers at least part of the core end surface.

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