CN1065155A - Amorphous steel core and coil block - Google Patents

Abstract

The iron core of transformer and coil block, this transformer have amorphous steel core and center on the coil of this iron core leg, wherein, very approaching shape of surrounding the coil window of this iron core leg are processed in the cross section of this iron core leg.

Description

Amorphous steel core and coil block

The present invention relates to the amorphous metal iron core and the coil block of transformer.

Invent and transfer the same assignee's of the present invention United States Patent (USP) the 4th jointly by Ballard and Klappert, 734, disclosed transformer and transformer of the present invention belong to same type in No. 975, and are cited in the application's book as immediate with reference to prior art.This transformer comprises the iron core of being made by many amorphous steel strips and is centered around prefabricated coil parts on the iron core leg respectively.Each prefabricated coil parts of this transformer generally are that the metal wire with the bag insulating barrier is wound on the bobbin of hollow electrical insulating material and makes.Usually, the inner surface of this air core coil frame surrounds the coil window of rectangle. and the latter is around the iron core leg that is associated.The sidewall be combined into that normally parallel end wall that this window is separated by two faces and two sides separate.

The cross section of above-mentioned coil window is not just in time to be rectangle.In general, its inside surface of side wall is with a little spills a little, and its each angle be rounding or bevel (owing to the related reason of prefabricated coil group technology).This is not just in time to be that the bobbin of rectangle makes the cross section of this window be difficult to be used for expeditiously holding the iron core leg, particularly has when being used for this close-fitting square-section of coil window peripheral when the iron core leg.The concave inside surface of sidewall forms unnecessary gap between coil window and this iron core leg, and the angle of its circle or bevel certainly will hinder the desired position at each angle of iron core leg.

The objective of the invention is to make this coil window to be used more effectively, particularly in such transformer, promptly, wherein besieged iron core leg is laminated along the direction from a sidewall of coil window to another sidewall by amorphous steel band, and the width of steel band extends between the end wall of this coil window.

Another purpose is a body plan iron core in such a way, that is, the iron core leg that is made of above-mentioned steel band has and the more approaching consistent cross sectional shape of going back coil window cross sectional shape.

A step during above-mentioned pattern amorphous steel core is made is an annealing operation, and in this procedure, the baking iron core is to eliminate the residual stress that forms in each making step of front under the proper temperature condition.This road annealing operation was finished before the iron core leg is inserted coil window.

According to the present invention, be during annealing, on iron core, to apply clamping force in such a way, that is, make the cross sectional shape of iron core leg more approaching consistent with the cross sectional shape of the coil window that will hold the iron core leg later on after annealing.

Implement iron core and coil block that a kind of mode of the present invention provides the following amorphous steel core transformer of making.Provide a kind of its window generally (but inaccuracy ground) be the coil component of square-section.The side be combined into that slightly is spill that normally parallel end face that this coil window is separated by the two sides and two sides separate.It is many stacked also to provide a kind of its iron core leg to comprise, the iron core of the amorphous steel band of basic alignment, and the two edges of every steel band separate with the width of band and its center places the central authorities of two edges.Described bandwidth is roughly the distance between the coil window both ends of the surface.The feature of described steel band is: there is the thickness bigger slightly than the marginal zone its center.Before iron core and coil component pairing, iron core is annealed to eliminate residual stress wherein by baking under a certain temperature conditions, then, make it slow cooling.During the annealing, apply extruding force by two edges district and push the iron core leg the steel band of iron core leg, make thickness before the thickness of these marginal zone legs and extruding compare to some extent and reduce, thereby, make the iron core leg cross sectional shape can be more consistent with the cross sectional shape of coil window.After like this annealing and extruding, the iron core leg to be inserted in the coil window, the distance that the thickness of iron core leg and coil window described slightly is between the face of spill equates.

For a better understanding of the present invention, necessary with reference to following description taken in conjunction with the accompanying drawings, in the accompanying drawing:

Fig. 1 is a side-looking elevation view of implementing the part section of a kind of transformer of the present invention.The iron core of transformer illustrates with section, and coil component illustrates with part section,

Fig. 2 is the part section end-view of one of coil component of Fig. 1;

Fig. 2 A is the amplification sectional view in the coil component inside lock zone of Fig. 2;

Fig. 3 is the enlarged diagram of some lamination of expression construction drawing 1 iron core;

Fig. 4 is the side elevation view of Fig. 1 iron core, and the hardware of the annealing usefulness that is added on the iron core is shown on it, for simplicity's sake, and not shown lamination or composition surface among Fig. 4;

Fig. 5 is the sectional drawing along Fig. 4 Vertical Centre Line 5-5 line of vision;

Fig. 6 is the profile of amplification that passes one of the iron core leg of the assembly of making, and simultaneously, illustrates around insulating component this iron core leg, that constitute coil window.

Below with reference to Fig. 1, iron core shown in the figure and coil block comprise the amorphous steel core 10 of closo, and this iron core comprises that the yoke 19 that a pair of leg 21 and two that vertically extends that separates flatly extends and the top and bottom of 23, two yokes are connected to each other with two legs respectively.Two coil components 28 are centered around respectively on the two iron core legs 21.

Iron core is made by the amorphous steel band, and for example, the amorphous steel that can buy from Allied-Signal company is as Metglas 2605-S2 amorphous steel.As in aforesaid U.S. Patent 4,734, disclosed in 975, with reference to its accompanying drawing 1 and 1A, can make iron core to above-mentioned band by the following method: make it form loop configuration 4 by coiling, radially this loop configuration is cut off again to form lamination piece 12, then, around mandrel one group one group ground of this lamination piece mutually folded (or nested) is got up, have the loop configuration 10 on ladder overlap joint composition surface 16 with formation.The another kind of method that produces the lamination of looping structure 10 is to be cut into this lamination with flat band,, in position band is cut off the lamination that has suitable length with generation that is.

The nominal thickness of every lamination of amorphous metal only is about a mil, and it is extremely thin comparing with general common thickness as the transformer core silicon steel sheet that is 7 to 12 mils.Therefore, preferably handle these laminations in groups, every group of lamination preferably has the thickness that is equivalent to above-mentioned silicon steel sheet one or two.In groups rather than monolithic handle lamination and help to make economy significantly.

Still with reference to patent 4,734, Figure 1A of 975 after the lamination esting being circularized structure, bends to semicircle to first tail band or local ring 18, and it is put in the cylindrical window 20 of described loop configuration.Similarly, second tail band or local ring 22 to put in the window 20 with the relation of tail band 18 overlap joints, these tail bands can be made with common silicon steel core steel, it has enough thickness, for example, seven mils, and the bottom mechanical support (intensity that these laminations almost not anti-iron core subside) of enough resiliences so that core lamination stack 12 to be provided arranged.Because these amorphous metal laminations are also quite crisp,, also play the protection lamination and prevent cracked and effect that fracture so these bottom local rings are finished various making steps and during use.Cover supporter in order to provide for core lamination stack 12, also can be again enclose 24, clamp the loop configuration 10 of the esting iron core that can see among this patent Figure 1A with the outside locking of the iron core steel band of one seven mil.The bottom bond end of locking circle is made of joint 24a, and this joint is drawn by the lock slots 24b in the bond end in the above and turned back, with the locking circle fastening of surrounding this esting iron core.

As the loop configuration 10 of above-mentioned Figure 1A that has made this patent after, bar structure 10 is placed on two suitable molded components (illustrating with 94 in Fig. 4 of the application's book), the latter reaches window 20, forces these two molded components separately to make structure 10 be configured as the rectangular shape shown in Fig. 2 of this patent then.Before this forming step, replace the base ring 22 of this patent Figure 1A with non-overlapped short base ring 22a.During forming step, these thicker bottom local rings 18 and 22a will become the U-shaped shape of Fig. 2.A function of these base rings is to give enough big bending radius (quite crisp nonmetal lamination 12 must adapt to the shapes of these windows) at the right-angled corner 20a place that has now become the core window 20 of rectangle, therefore, significantly reduces the possibility that fractures.During the iron core forming step, when molded component embedded iron core, these bottom local rings also can play the effect of resilient coating, effectively prevented to damage, and particularly prevented the damage of innermost layer core lamination stack.The skin of wound core 10 locking circle 24 also can play the effect of resilient coating in forming process, is used to protect the outermost layer core lamination stack.

Be processed at iron core after the rectangular shape of Fig. 2 of described patent, annealed sheet (is illustrated in the application's book Fig. 4 and Fig. 5 best, be about to below be illustrated) be added on the iron core near the inside and outside surface of each iron core leg, subsequently, anneal under the magnetic field of iron core in suitable annealing furnace.Annealing is carried out in a well-known manner, in order that eliminate the residual stress in the amorphous metal lamination, these stress be included in cutting, esting and shaping or each step that formalizes in the stress given.When annealing had been finished, the annealed sheet of ubi supra just was removed, but was after the bonding operation in edge that is about to explanation.During annealing, iron core is heated to the temperature that is enough to eliminate stress in the amorphous metal lamination, for example, about 360 ℃, still, this temperature is not sufficient to the locking circle 24 of outside or described bottom local ring 18 and 22a annealing, because their general full iron core steel or similar material are made.As the part of annealing operation, described iron core was maintained at this temperature neighbouring about 4 hours, then slowly cooling.

Referenced patent 4,734 again, and Fig. 2 of No. 975 after with core annealing, is coated onto suitable bonding agent on the lateral edge of exposing of iron core both sides amorphous metal lamination 12, form thin layer 26.This bonding agent is coated with liquid form, the mode of handy brush, and subsequently, its is dry and hard and form the resilient coating of one deck, just the edge of lamination is bonded together.As what in Fig. 2 of described patent, can see, this edge join layer 26a along the line and ending, it is just in time less than the free end 18a of bottom local ring 18, or almost flushes with it.Like this, knitting layer 26 is along the total length of top yoke 19, and along the major part (terminating in from comprising the not far part of corner joint bonding land 17, that engage with following yoke 23) of the length of interconnected leg 21, lamination 12 is tightened to an integral body.Like this, in removing following yoke 23, lead to and be included in several sections laminations in the bonding land 17, adapting in conjunction with patent 4,734, when the described iron core of Fig. 3 of No. 975 and Fig. 4 is tightened step, effectively limit the mutual disorientation of amorphous metal lamination 12.It is to be noted that bottom local ring 22a is the scope of excess edge knitting layer boundary line 26a, therefore, when the iron core preparation is tightened around transformer coil, can freely remove.Yet bottom local ring 18 and locking circle 24 bond on the lamination 12 with the edge bonding way along the major part of their length.During adhesive-applying, very careful to avoid the infiltration between lamination, because this can influence the loss of iron core unfriendly.SCOTCH-GRIP 826 or SCOTCH-CLAD EC 776 are the edge bonding agents that are fit to, and the both can buy from 3M company.

Carry out above-mentioned edge bonding after, Fig. 2 of the described patent of outside locking circle 24() by stretching joint 24a and it is untied from lock slots 24b open.Along with the top yoke 19 that is supported by leg 21 extends downwards therefrom, the non-edge join of the outer ring of described unlatching partly springs back to the position shown in this patent Fig. 3.Similarly, the halves 23a of following yoke no longer is subjected to the constraint of outside locking circle, and this patent hanging position shown in Figure 3 that drops down, 17 places, bonding land under being included in the yoke are separated from each other.Can see that edge join layer 26 adapts to the requirement of opening iron core easily, simultaneously, restriction lamination 12 relatively moves in their most of scope of peripheral length.

For facility is tightened the operation of iron core, the iron core leg 21 that the halves 23a of the following yoke that extends between two corner regions at local engagement district 17 and place, following yoke end is oriented substantially with their attachings aligns.Therefore, this iron core is with regard to the profile that takes the shape of the letter U substantially, and having is straight leg basically, and they comprise original leg 21 and yoke half 23a of that aimed at afterwards.The leg of the extension of (referring to Fig. 3 of this patent) this U-shaped structure can easily slip over the window 28a of two transformer coil groups 28, and this two coil groups is fit to respectively encircle original leg 21 and the very little gap of band only.

After the extension leg of this U-iron cored structure has been inserted into coil groups, the two halves of the joint at described leg physical end place is immersed in the lightweight oil groove, illustrated as Fig. 4 of this patent, or spray with this oil.The two halves of this joint is moved to the position on recasting composition surface then, and closed again thus this iron-core workpiece.As patent 4,734, described in 975,, be convenient to the recasting on this composition surface by means of the described oil on the two halves of joint.After this, locking circle 24 is closed once more, and this joint 24a fastening once more is to clamp the locking circle on iron core-closed once more.Edge join layer 26 is guaranteed when iron core is closed once more not disorientation of lamination 12.Thereby this iron core still can present the identical shape that is had when annealing with it basically after the assembling of finishing loop construction, like this, introduces all stress in the lamination during iron core is tightened, and has in fact all obtained elimination effectively.

With reference to Fig. 2 of the application, each in the coil component 28 comprises low-voltage coil 128 and high-tension coil 130, and described high-tension coil centers on described low-voltage coil, and, suitably added insulating barrier betwixt.Low-voltage coil 128 is by the hollow bobbin of being made by electrical insulating material 60 is placed (this mandrel is contained within the hollow bobbin) of making on the mandrel (not shown).Then, insulated conductor 62 successively is wrapped on the bobbin 60 of hollow, until reach till the desired number of turn.Just high-tension coil 130 be wrapped in described low-voltage coil 128 on thereafter.Take down mandrel then; Drawn the profile of coil groups 28 among Fig. 2 simultaneously with the part section form.As well-known in the art, it is that this low-voltage coil can be wrapped in bobbin 60 with the conductive strips that have the thin insulating sheet up and down and makes above that another kind side goes, and the width of band and sheet is substantially equal to the height of coil.

As shown in Figure 2, hollow insulating bobbin 60 comprises a coil window 28a of square-section substantially.This window 28a is separated substantially by the two sides that separate on parallel end wall 67 and two sides, sidewall 69 be combined intos of spill inner face 70 slightly.Every sidewall 69 is by a corner 72 end wall combinations adjacent thereto.Each of these corners 72 is rounding or bevel, in the shape of typical oblique angle shown in the zoomed-in view of Fig. 2 A.By the characteristic oblique angle and on-right angle, corner 72, and the feature that is the face 70 of spill slightly, obviously, coil window 28a is not to be rectangle definitely.

If described window section just in time is a rectangle,, can effectively utilize the coil window cross section that holds the iron core leg with comparalive ease certainly if particularly the iron core leg also has the square-section.But owing to the reason (related with being manufactured with of coil groups) of reality, form just in time is that the coil window cross section of rectangle is difficult.The corner at rounding or oblique angle for prevent coil-conductor too sharp bend need, and the spill profile of sidewall also needs with mechanical strength for giving bobbin 60.

In order more effectively to utilize the area of section of coil window 28a, the present invention has changed the cross sectional shape of relevant iron core leg 21, makes it approaching more consistent with the cross sectional shape of coil window.For this reason, during above-mentioned annealing operation, the present invention is added to extruding force on the described iron core leg, and this extruding force has the effect of iron core leg thickness in two zones that reduce leg, and this two zone is positioned at end walls 67 parts of adjacent coils window.

Why the present invention can utilize above-mentioned extruding force to reduce iron core leg thickness, is the core lamination stack of making because of by the amorphous metal band, and in general, its center is than its marginal portion thicker slightly (for example, thick 5% to 20%).This describes in Fig. 3 of the application, illustrates on the figure that some have been overweening aspect thickness, and has above-mentioned difference in thickness, and the lamination of pressing the direction lamination of iron core leg thickness T.Fig. 3 describes they clampings are used to these laminations in the past of annealing.Because in general these laminations are more thinner slightly than their central area 80 at 75 places, edge of pressing close to them, so in their 75 zones, edge, between each lamination very narrow space 82 will be arranged.In view of the above, added extruding force F steps up each lamination together in 75 zones, edge if be used in, and then the iron core leg thickness in the fringe region will reduce, and the numerical value that reduces is substantially equal to the summation of these narrow gap 82 thickness.

With reference to the application Fig. 3,4 and 5, by providing clamping plate 90 and 92, can in the zone at edge 75, add extruding force to each iron core leg, this clamping plate has the clamping area that is used to be pressed over the female shapes on the iron core leg.When clamping plate is pressed together, they will be pressed in the iron core leg and press close on the outside and inner surface in 75 zones, edge.

For clamping plate is pressed together, the present invention relies on shaping piece 94 and a pair of steel to clamp tape 95, and every ribbon toroid is put whole iron-core workpiece on the spot.Above-mentioned iron core is transformed into the shaping operation of rectangular shape from circle after, the shaping piece is just stayed on the position.At each end of described shaping piece, an interior clamping plate 92 is inserted between the inner surface and described shaping piece termination of an iron core leg.Add another clamping plate 90 at the outer surface place of each iron core leg.As shown in Figures 4 and 5, tape 95 wound core bodies extend around two iron core legs 14 and two outside clamping plates 90.

When just in time before core annealing, tape 95 being fastened, the clamping plate 90 and 92 that each side of each leg is located lumps together forcibly, thereby push the iron core leg between them, during this clamping, shaping piece 94 keeps a fixing interval between inner face clamping plate 92.After tape was fastened, a general buckle 97 on every band 95 is clamped in it to band to be fastened in the state, so just during annealing operation subsequently, is keeping extruding force on each leg.

As already pointed out, the extruding force that is produced by the shrink link taut band reduces the thickness of iron core leg in pressing close to 75 zones, lamination edge.This has makes those laminations crooked or bow curved effect of iron core leg except that the close median surface 99 of Fig. 5.Such amount of bow is along with increasing with the increasing of median surface 99 distances.Annealing operation plays elimination and the effect of any residual stress that in amorphous metal lamination produce curved by this bending or bow.

After annealing, when clamping plate 90,92 and band 95 are still on original position, above-mentioned knitting layer 26 is added on the lateral edge 75 of the exposure of lamination 12 on the iron core leg both sides.When this bonding agent is dry and hard, the marginal zone of lamination 12 is bonded together, and, lamination is remained on clamp on the position of being occupied during the annealing.Only dry and hard at bonding agent, and after lamination has been bonded together, just remove clamping plate 90,92 and band 95.As already pointed out, also bonding inner foundation ring 18 of this bonding agent and outside locking circle 24, and make these circles remain on the curved state of a kind of bow slightly thus, simultaneously, keep adaptive closely the joint with the remainder of related iron core leg.

Fig. 6 provides the figure that schematically illustrates of relevant iron core leg 21, improves in the cross section part as mentioned above, has a cross-sectional shape that more closely accords with coil window 28a cross sectional shape.The thickness that has reduced at the edge of lamination 75 place's legs makes the corner regions of iron core be avoided the oblique angle at coil window corner 72 places, and, outsidely the outside of iron core leg can more closely be conformed to the concave inside surface that coil window is pressed close to inner surface with the arcuate profile of inner lamination.The adhesive of bonded edge illustrates with 26 in Fig. 6.

By means of a kind of iron core leg cross sectional shape that more closely conforms to coil window is provided, make coil window can make forr a short time, this means for coil-conductor, can use short lead, and the space that coil component occupied will be littler.These features cause the economy of making aspect.

Though clamping plate has been utilized during annealing as the leg that clamps the amorphous metal iron core before this, but just these plates known to the inventor are flat member basically, main clamping force is added on the center 100 of iron core leg (referring to Fig. 5), and constitutes on the center of iron core leg lamination 12.In some cases, when adopting this flat clamping plate, at the plate edge place described plate is strained together along a side of iron core by the clamping force that clamps the band generation, but the opposite side along iron core makes them separate at the plate edge place, that is to say, cause the inclination of clamping plate, in general, the plate edge place that is positioned at buckle 97 strains described plate together.This gap tilt effect of clamping plate makes the iron core leg thinner than opposite side significantly in a side.This is undesirable, because it permeates more after-applied bonding agent (26) between the lamination on the thicker side of iron core.The difference of so further increasing in the opposite side place of leg iron core leg thickness.The iron core leg of this latter's form has the cross sectional shape of coil window than the iron core leg that is rectangle fully even consistency still less.

Though, preferably each iron core leg is adopted the spill clamping plate in the both sides of iron core leg thickness,, if only use a notch plate, still can realize some advantage of the present invention, at this moment preferably outside clamping plate is a female shapes, and interior plate is a flat shape.Therefore, main aspect of the present invention is intended to comprehensive a kind of method, and this method is only used such spill clamping plate, and obtains iron-core workpiece thus.In addition, in some transformer, it is a sidewall (69) on plane basically that hollow bobbin 60 its final forms of coil component will have, and another sidewall (69) then still remains spill as shown basically.Be this transformer when making iron core, during annealing, only adopting a spill clamping plate (for example, Fig. 5 90), as shown in FIG., making this side of leg be convex a little in a side of iron core leg.The convex surface of this leg is to locate like this, and promptly when this leg injected this coil component, the convex surface of leg was pressed close to the concave surface of bobbin 60, just can produce desired closely cooperating between such iron core leg and the coiling frame 60.In this embodiment, be that adopting is flat clamping plate basically during annealing in the iron core leg side of flat sidewall substantially to the bobbin of preparing to press close to coil component in the location 60.

Although more than illustrate and described a specific embodiment of the present invention, but obviously for the people who is familiar with the one's own profession technology, do not breaking away under the situation aspect main of the present invention, can make and resemble the described variations and modifications of a joint, therefore, the application plans to relate to all changes and the modification in spirit of the present invention and the scope.

Claims (4)

1, a kind of iron core and coil block that is used for the amorphous metal appendiron core transformer, they comprise:

A) has the coil component of the coil window of square-section substantially, the side be combined into that normally parallel end face that this coil window is separated by the two sides and two sides separate, wherein, at least one side is a spill slightly, two sides have two petiolareas and center of contiguous described end face separately, and the spacing of the center of two sides is less times greater than the spacing of petiolarea.

B) has the iron core of iron core leg, this iron core leg is assemblied within the described coil window and is included in esting on the iron core leg thickness direction, the amorphous steel band of substantial alignment, every steel band has two edges that separated by bandwidth and the center that is positioned at described two edge central authorities, bandwidth is roughly the distance between the described coil window both ends of the surface, the feature of described steel band is that its center has big slightly thickness than the marginal zone, described iron core leg has such thickness, promptly, two marginal zones at described steel band, this thickness is significantly less than the leg thickness in described steel band center, thereby, make described leg can more closely be assemblied in described coil window.

2, the assembly of claim 1 is characterized in that: the edge of described steel band is in each side substantial alignment of the center of steel band, and usefulness adhesive bond material adhesive together.

3, the assembly of claim 1 is characterized in that: during core annealing, applies the extruding force that reduces leg thickness by two marginal zones and pushes described iron core leg at steel band, thereby, reduce the thickness in the described steel band edge district of described leg,

Thus, make described steel band after annealing and extruding, not have residual stress basically.

4, the assembly of claim 3 is characterized in that: in each side of described steel band center, the edge of described steel band aligns basically, and combines with the adhesive bond material.

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