CN104835616A - Novel circular-ring-shaped high-power electric reactor and manufacturing method thereof - Google Patents
Novel circular-ring-shaped high-power electric reactor and manufacturing method thereof Download PDFInfo
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- CN104835616A CN104835616A CN201510288201.0A CN201510288201A CN104835616A CN 104835616 A CN104835616 A CN 104835616A CN 201510288201 A CN201510288201 A CN 201510288201A CN 104835616 A CN104835616 A CN 104835616A
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Abstract
The invention discloses a novel circular-ring-shaped high-power electric reactor. The electric reactor comprises a magnetic core and a coil. The magnetic core is a circular-ring-shaped magnetic core formed by two identical semicircular-ring-shaped magnetic core bodies in a combined mode, the diameter of the circular-ring-shaped magnetic core ranges from 7 inches-20 inches, and the magnet density of the circular-ring-shaped magnetic core ranges from 5.5 g/cm<3> to 6.2 g/cm<3>. The two semicircular-ring-shaped magnetic core bodies are sleeved with the coil which is a spiral varnished wire coil formed by a flat wire in a vertical winding mode. The semicircular-ring-shaped magnetic core bodies are formed by pouring a magnetic composite material composed of ferromagnetic powder and high-temperature resin adhesive through a semicircular-ring-shaped mould. The electric reactor is simple in structure, low in production cost, light in weight, low in noise, low in loss, good in surface heat dissipation and long in service life; the process is simple, and automatic operation is easy to achieve; the utilization rate of the magnetic core is high, magnetic leakage is small, and the EMI effect is good.
Description
Technical field
The present invention relates to inductance component technical field, specifically a kind of high-power annular Novel reactor and manufacture method thereof.
Background technology
Reactor, as reactive power compensation means, is indispensable in electric power system.Reactor is used for limiting the rush of current that grid voltage mutation and operating process voltage cause; the spike comprised in level and smooth supply voltage; or the voltage effects produced during level and smooth bridge rectifier commutation; effectively protect frequency converter and improve power factor; it can stop the interference from electrical network, can reduce again the harmonic current of rectification unit generation to the pollution of electrical network.
The complicate fabrication process of tradition silicon steel reactor, production cost is high.Its manufacturing process mainly comprises following content:
1, the coiling of coil: coiling needs Copper Foil or aluminium foil, insulating material Nomex paper, epoxy resin bar and the material and facility such as epoxy resin board, winding mould.Copper Foil and aluminium foil are used for conduction current, form magnetic field.Nomex paper is used for coil inside insulation.Its winding process mainly comprises internal mold assembling, inner copper line welding, the insulation of Nomex paper and the process such as Copper Foil coiling, outer copper line welding.The raw material that this operation needs are many, and the prices of raw and semifnished materials are expensive, and Copper Foil winding equipment drops into comparatively large in addition, and coiling efficiency is low, and mould costly, causes high production cost.
2, the making of silicon steel core: the material that traditional iron core uses is silicon steel sheet, the production process of silicon steel sheet is complicated, and particularly grain-oriented Si steel sheet, domestic at present only have large-scale steel mill of several family such as Baosteel, Wuhan Iron and Steel Plant to manufacture, and cost is high.Silicon steel sheet, through the itemize of band, then through slitting with horizontally to cut, is made the silicon steel sheet material of required specification, is carried out closed assembly fix finally by folder from top to bottom to silicon steel sheet material.The superposition Making programme of iron core is complicated, and manufacture requirements is high, and mechanization degree is low, and the shearing of silicon steel sheet and closed assembly easily damage human body due to sharp edge and burr, increase industrial accident rates, govern the production efficiency of iron core.
3, assemble: traditional silicon steel reactor needs through gripping silicon steel sheet lamination assembling up and down and fixing, center pillar lamination assembling.Middle column iron core needs distributed air gaps, and regulates air gap thickness, and then adjusting inductance.Coil and iron core also need to do insulation processing in assembling process in addition, to meet the electric property of inductance.Last process of carrying out dipping lacquer and baking again.
Generally speaking, the production process of traditional silicon steel reactor is complicated, and floor space is large, and equipment and personnel have high input, and need the manufacturers produce of specialty, and the production cycle is long, efficiency is low, becomes to produce cost high, governs the development of reactor.
In addition traditional silicon steel reactor noise is large, bulky, brings very large impact to surrounding environment and installation, and weak heat-dissipating, easily leakage field, EMI weak effect etc. all govern the development of reactor.Particularly in the running environment of big current (electric current is greater than 100A), high frequency (frequency is higher than 5KHz), traditional silicon steel sheet reactor is comparatively difficult to meet application requirement.
Given this, the active demand that a kind of technique is simple, with low cost, electromagnetic performance is good Novel reactor is current electron electric power fast development is developed.
Summary of the invention
In order to solve in conventional reactor, iron core noise is large, volume is large and production process is complicated, high in cost of production technical problem, particularly conventional reactor are difficult at big current (electric current is greater than 100A), high frequency (frequency is higher than 5KHz) problem meeting application requirement.The invention provides that a kind of noise is little, inductance performance good, leakage field is little, volume is little, excellent radiation performance, loss are low and are applicable to the high-power annular Novel reactor applied in big current (electric current is greater than 100A), high frequency (frequency is higher than 5KHz) environment.
For achieving the above object, the invention provides following technical scheme:
A kind of high-power annular Novel reactor, comprise magnetic core and coil, described magnetic core is by the toroidal cores of two identical semi-circular shape core combination, and the diameter of described toroidal cores is 7 ~ 20 inches, and the magnet density of described toroidal cores is 5.5g/cm
3~ 6.2g/cm
3described coil is enclosed within two described semi-circular shape magnetic cores, described coil turns to spiral enamel wire coil by flat wire is vertical, and the magnetic composite that described semi-circular shape magnetic core is made up of ferromagnetic powder and high-temperature resin glue is built by semi-annular mould and made.
Further, the center of an end face of described semi-circular shape magnetic core offers cylinder shape groove, and the center of another end face of described semi-circular shape magnetic core is provided with the cylindrical boss coordinated with described cylinder shape groove.
Further, the cross section of described semicircular ring magnetic core is circular or oval or arbitrary polygon.
Further, two described semi-circular shape magnetic cores are fixedly connected with by glue.
The present invention also provides a kind of manufacture method of high-power annular Novel reactor, comprises the following steps:
1) coiling enamel wire coil in the shape of a spiral;
2) by resin glue 70 ~ 80wt%, coupling agent 5 ~ 10wt%, promoter 15 ~ 20wt% mixing and stirring, high-temperature resin glue is obtained;
3) ferromagnetic powder and described high-temperature resin glue are pressed ferromagnetic powder 88 ~ 94wt%, high-temperature resin glue 6 ~ 12wt% mixing and stirring, obtain magnetic composite;
4) be expelled in semi-annular mould by described magnetic composite, pour into a mould two semi-circular shape magnetic cores respectively, the demoulding after 125 ~ 140 DEG C of solidification 1.5 ~ 2.5h, obtains two identical semi-circular shape magnetic cores;
5) spiral helicine described enamel wire coil is inserted in two described semi-circular shape magnetic cores respectively, then with glue, two semi-annular magnetic cores is merged into a circle ring magnetic core, namely make described high-power annular Novel reactor.
Further, described resin glue is modified epoxy silicones.
Further, described coupling agent is mercapto hydroxypropyl methyl dimethoxysilane.
Further, described promoter is isophthalic two methanediamine.
Further, the grain size proportion of described ferromagnetic powder is as follows :-100 order ~ 200 order: 20 ~ 30wt% ,-200 order ~ 500 order: 30 ~ 40wt% ,-500 orders: 30 ~ 50wt%.
Further, described ferromagnetic powder is at least one in iron silica flour, iron powder, iron aluminum silicon powder, iron nickel powder and iron silicochromium powder.
Compared with prior art, the invention has the beneficial effects as follows: structure of the present invention is simple, simplifies production technology, save large number quipments and drop into, and decrease the floor space of production and saved the materials such as a large amount of Copper Foils, reduce the Productive statistics of whole reactor; Coiling and the production of casting magnetic core easily realize automation, and assembling is simple, saves a large amount of human resources;
Compare traditional iron core reactor, this Novel reactor also has following feature performance benefit:
1, reactor is lightweight, and than 500A, traditional iron core reactor of 300 μ H is light by about 1/3, facilitates installation and the transportation of reactor;
2, reactor outward appearance is the circular ring type magnetic core with vertical coiling, and surface area is large, and thermal diffusivity is good, extends the useful life of reactor;
3, magnetic core surrounds by founding coiling entirety, and utilance is high, and leakage field is few, and EMI is effective;
4, magnetic core is made up of Insulating Ferromagnets powder, and insulation property are fabulous, and the eddy current loss of magnet is low, has saved a large amount of energy consumption;
5, reactor noise is low, little to the pollution of surrounding environment.
Accompanying drawing explanation
Fig. 1 is the structural representation of a kind of high-power annular Novel reactor of the present invention.
Embodiment
Below in conjunction with the accompanying drawing in the embodiment of the present invention, be clearly and completely described the technical scheme in the embodiment of the present invention, obviously, described embodiment is only the present invention's part embodiment, instead of whole embodiments.Based on the embodiment in the present invention, those of ordinary skill in the art, not making the every other embodiment obtained under creative work prerequisite, belong to the scope of protection of the invention.
Embodiment 1
A kind of high-power annular Novel reactor, comprise magnetic core 1 and coil 2, described magnetic core 1 is the toroidal cores be formed by fixedly connecting by glue by two identical semi-circular shape magnetic cores, the cross section of described semicircular ring magnetic core is circular, the diameter of described toroidal cores is 20 inches, and the magnet density of described toroidal cores is 6.2g/cm
3described coil 2 is enclosed within two described semi-circular shape magnetic cores, described coil 2 turns to spiral enamel wire coil by flat wire is vertical, and the magnetic composite that described semi-circular shape magnetic core is made up of ferromagnetic powder and high-temperature resin glue is built by semi-annular mould and made.
Above-mentioned high-power annular Novel reactor is that manufacture by the following method forms, and comprises the following steps:
1) automatic coil winding machine is utilized to turn to spiral enamel wire coil by vertical for flat wire
2) epoxy silicone, mercapto hydroxypropyl methyl dimethoxysilane, isophthalic two methanediamine are pressed the weight ratio mixing and stirring of 7:1:2, obtain high-temperature resin glue;
3) ferromagnetic powder and described high-temperature resin glue are pressed the weight ratio mixing and stirring of 94:6, obtain magnetic composite, described ferromagnetic powder is mixed in the ratio of 2:3:5 by the iron silica flour of-100 order ~ 200 orders ,-200 order ~ 500 orders ,-500 orders three kinds of grain size categories;
4) be expelled in semi-annular mould by described magnetic composite, pour into a mould two semi-circular shape magnetic cores respectively, the demoulding after 130 DEG C of solidification 2h, obtains two identical semi-circular shape magnetic cores;
5) spiral helicine described enamel wire coil is inserted in two described semi-circular shape magnetic cores respectively, then with glue, two semi-annular magnetic cores is merged into a circle ring magnetic core, namely make described high-power annular Novel reactor.
Embodiment 2
A kind of high-power annular Novel reactor, comprise magnetic core 1 and coil 2, described magnetic core 1 is the toroidal cores be formed by fixedly connecting by glue by two identical semi-circular shape magnetic cores, the cross section of described semicircular ring magnetic core is circular, the diameter of described toroidal cores is 15 inches, and the magnet density of described toroidal cores is 5.9g/cm
3described coil 2 is enclosed within two described semi-circular shape magnetic cores, described coil 2 turns to spiral enamel wire coil by flat wire is vertical, and the magnetic composite that described semi-circular shape magnetic core is made up of ferromagnetic powder and high-temperature resin glue is built by semi-annular mould and made.
Above-mentioned high-power annular Novel reactor is that manufacture by the following method forms, and comprises the following steps:
1) automatic coil winding machine is utilized to turn to spiral enamel wire coil by vertical for flat wire
2) epoxy silicone, mercapto hydroxypropyl methyl dimethoxysilane, isophthalic two methanediamine are pressed the weight ratio mixing and stirring of 75:7:18, obtain high-temperature resin glue;
3) ferromagnetic powder and described high-temperature resin glue are pressed the weight ratio mixing and stirring of 9:1, obtain magnetic composite, described ferromagnetic powder is mixed in the ratio of 25:35:40 by the iron silica flour of-100 order ~ 200 orders ,-200 order ~ 500 orders ,-500 orders three kinds of grain size categories;
4) be expelled in semi-annular mould by described magnetic composite, pour into a mould two semi-circular shape magnetic cores respectively, the demoulding after 125 DEG C of solidification 2.5h, obtains two identical semi-circular shape magnetic cores;
5) spiral helicine described enamel wire coil is inserted in two described semi-circular shape magnetic cores respectively, then with glue, two semi-annular magnetic cores is merged into a circle ring magnetic core, namely make described high-power annular Novel reactor.
Embodiment 3
A kind of high-power annular Novel reactor, comprise magnetic core 1 and coil 2, described magnetic core 1 is the toroidal cores be formed by fixedly connecting by glue by two identical semi-circular shape magnetic cores, the cross section of described semicircular ring magnetic core is circular, the diameter of described toroidal cores is 7 inches, and the magnet density of described toroidal cores is 5.5g/cm
3described coil 2 is enclosed within two described semi-circular shape magnetic cores, described coil 2 turns to spiral enamel wire coil by flat wire is vertical, and the magnetic composite that described semi-circular shape magnetic core is made up of ferromagnetic powder and high-temperature resin glue is built by semi-annular mould and made.
Above-mentioned high-power annular Novel reactor is that manufacture by the following method forms, and comprises the following steps:
1) automatic coil winding machine is utilized to turn to spiral enamel wire coil by vertical for flat wire
2) epoxy silicone, mercapto hydroxypropyl methyl dimethoxysilane, isophthalic two methanediamine are pressed the weight ratio mixing and stirring of 80:5:15, obtain high-temperature resin glue;
3) ferromagnetic powder and described high-temperature resin glue are pressed the weight ratio mixing and stirring of 88:12, obtain magnetic composite, described ferromagnetic powder is mixed in the ratio of 3:4:3 by the iron silica flour of-100 order ~ 200 orders ,-200 order ~ 500 orders ,-500 orders three kinds of grain size categories;
4) be expelled in semi-annular mould by described magnetic composite, pour into a mould two semi-circular shape magnetic cores respectively, the demoulding after 140 DEG C of solidification 1.5h, obtains two identical semi-circular shape magnetic cores;
5) spiral helicine described enamel wire coil is inserted in two described semi-circular shape magnetic cores respectively, then with glue, two semi-annular magnetic cores is merged into a circle ring magnetic core, namely make described high-power annular Novel reactor.
Embodiment 4
A kind of high-power annular Novel reactor, comprise magnetic core 1 and coil 2, described magnetic core 1 is the toroidal cores be formed by fixedly connecting by glue by two identical semi-circular shape magnetic cores, the cross section of described semicircular ring magnetic core is circular, the diameter of described toroidal cores is 7 inches, and the magnet density of described toroidal cores is 6.0g/cm
3described coil 2 is enclosed within two described semi-circular shape magnetic cores, described coil 2 turns to spiral enamel wire coil by flat wire is vertical, and the magnetic composite that described semi-circular shape magnetic core is made up of ferromagnetic powder and high-temperature resin glue is built by semi-annular mould and made.
Above-mentioned high-power annular Novel reactor is that manufacture by the following method forms, and comprises the following steps:
1) automatic coil winding machine is utilized to turn to spiral enamel wire coil by vertical for flat wire
2) epoxy silicone, mercapto hydroxypropyl methyl dimethoxysilane, isophthalic two methanediamine are pressed the weight ratio mixing and stirring of 7:1:2, obtain high-temperature resin glue;
3) ferromagnetic powder and described high-temperature resin glue are pressed the weight ratio mixing and stirring of 9:1, obtain magnetic composite, described ferromagnetic powder is mixed in the ratio of 2:3:5 by the iron nickel powder of-100 order ~ 200 orders ,-200 order ~ 500 orders ,-500 orders three kinds of grain size categories;
4) be expelled in semi-annular mould by described magnetic composite, pour into a mould two semi-circular shape magnetic cores respectively, the demoulding after 130 DEG C of solidification 2h, obtains two identical semi-circular shape magnetic cores;
5) spiral helicine described enamel wire coil is inserted in two described semi-circular shape magnetic cores respectively, then with glue, two semi-annular magnetic cores is merged into a circle ring magnetic core, namely make described high-power annular Novel reactor.
According to embodiment 1 ~ 4, method manufactures the reactor of same size, does electric property contrast test, obtain following table data with traditional iron core reactor:
To those skilled in the art, obviously the invention is not restricted to the details of above-mentioned one exemplary embodiment, and when not deviating from spirit of the present invention or essential characteristic, the present invention can be realized in other specific forms.Therefore, no matter from which point, all should embodiment be regarded as exemplary, and be nonrestrictive, scope of the present invention is limited by claims instead of above-mentioned explanation, and all changes be therefore intended in the implication of the equivalency by dropping on claim and scope are included in the present invention.Any Reference numeral in claim should be considered as the claim involved by limiting.
In addition, be to be understood that, although this specification is described according to execution mode, but not each execution mode only comprises an independently technical scheme, this narrating mode of specification is only for clarity sake, those skilled in the art should by specification integrally, and the technical scheme in each embodiment also through appropriately combined, can form other execution modes that it will be appreciated by those skilled in the art that.
Claims (10)
1. a high-power annular Novel reactor, comprise magnetic core and coil, it is characterized in that, described magnetic core is by the toroidal cores of two identical semi-circular shape core combination, the diameter of described toroidal cores is 7 ~ 20 inches, and the magnet density of described toroidal cores is 5.5g/cm
3~ 6.2g/cm
3described coil is enclosed within two described semi-circular shape magnetic cores, described coil turns to spiral enamel wire coil by flat wire is vertical, and the magnetic composite that described semi-circular shape magnetic core is made up of ferromagnetic powder and high-temperature resin glue is built by semi-annular mould and made.
2. high-power annular Novel reactor according to claim 1, it is characterized in that, the center of an end face of described semi-circular shape magnetic core offers cylinder shape groove, and the center of another end face of described semi-circular shape magnetic core is provided with the cylindrical boss coordinated with described cylinder shape groove.
3. high-power annular Novel reactor according to claim 1, is characterized in that, the cross section of described semicircular ring magnetic core is circular or oval or arbitrary polygon.
4. high-power annular Novel reactor according to claim 1, is characterized in that: two described semi-circular shape magnetic cores are fixedly connected with by glue.
5. a manufacture method for high-power annular Novel reactor, is characterized in that, comprise the following steps:
1) coiling enamel wire coil in the shape of a spiral;
2) by resin glue 70 ~ 80wt%, coupling agent 5 ~ 10wt%, promoter 15 ~ 20wt% mixing and stirring, high-temperature resin glue is obtained;
3) ferromagnetic powder and described high-temperature resin glue are pressed ferromagnetic powder 88 ~ 94wt%, high-temperature resin glue 6 ~ 12wt% mixing and stirring, obtain magnetic composite;
4) be expelled in semi-annular mould by described magnetic composite, pour into a mould two semi-circular shape magnetic cores respectively, the demoulding after 125 ~ 140 DEG C of solidification 1.5 ~ 2.5h, obtains two identical semi-circular shape magnetic cores;
5) spiral helicine described enamel wire coil is inserted in two described semi-circular shape magnetic cores respectively, then with glue, two semi-annular magnetic cores is merged into a circle ring magnetic core, namely make described high-power annular Novel reactor.
6. manufacture method according to claim 5, is characterized in that, described resin glue is modified epoxy silicones.
7. manufacture method according to claim 5, is characterized in that, described coupling agent is mercapto hydroxypropyl methyl dimethoxysilane.
8. manufacture method according to claim 5, is characterized in that, described promoter is isophthalic two methanediamine.
9. manufacture method according to claim 5, is characterized in that, the grain size proportion of described ferromagnetic powder is as follows :-100 order ~ 200 order: 20 ~ 30wt% ,-200 order ~ 500 order: 30 ~ 40wt% ,-500 orders: 30 ~ 50wt%.
10. manufacture method according to claim 5, is characterized in that, described ferromagnetic powder is at least one in iron silica flour, iron powder, iron aluminum silicon powder, iron nickel powder and iron silicochromium powder.
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| WO2016192092A1 (en) * | 2015-06-04 | 2016-12-08 | 深圳市铂科磁材有限公司 | Novel high-power annular reactor and manufacturing method therefor |
| CN106653272A (en) * | 2017-02-08 | 2017-05-10 | 久利科技（苏州）有限公司 | Annular sensor with high radiating capacity and flat wires wound in upright manner and method for preparing annular sensor |
| CN107464650A (en) * | 2017-08-10 | 2017-12-12 | 深圳市铂科新材料股份有限公司 | A kind of metal soft magnetic powder core of high temperature heat-resistant processing |
| CN107578872A (en) * | 2017-08-10 | 2018-01-12 | 深圳市铂科新材料股份有限公司 | A kind of preparation method of the metal soft magnetic powder core of high temperature heat-resistant processing |
| CN108962546A (en) * | 2018-08-30 | 2018-12-07 | 上海羿煜电子科技有限公司 | A kind of heavy-current inductor |
| CN112652437A (en) * | 2021-01-15 | 2021-04-13 | 江苏瑞德磁性材料有限公司 | Preparation method of metal soft magnetic powder core with low forming pressure and high production efficiency |
| CN113096950A (en) * | 2021-04-09 | 2021-07-09 | 江苏瑞德磁性材料有限公司 | Preparation method of soft magnetic powder core with built-in coil |
| CN113096951A (en) * | 2021-04-09 | 2021-07-09 | 江苏瑞德磁性材料有限公司 | Preparation method of annular metal soft magnetic powder core with circular cross section |
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| CN113096950A (en) * | 2021-04-09 | 2021-07-09 | 江苏瑞德磁性材料有限公司 | Preparation method of soft magnetic powder core with built-in coil |
| CN113096951A (en) * | 2021-04-09 | 2021-07-09 | 江苏瑞德磁性材料有限公司 | Preparation method of annular metal soft magnetic powder core with circular cross section |
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