EP2597656A1 - Réacteur - Google Patents

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Publication number
EP2597656A1
EP2597656A1 EP20110809451 EP11809451A EP2597656A1 EP 2597656 A1 EP2597656 A1 EP 2597656A1 EP 20110809451 EP20110809451 EP 20110809451 EP 11809451 A EP11809451 A EP 11809451A EP 2597656 A1 EP2597656 A1 EP 2597656A1
Authority
EP
European Patent Office
Prior art keywords
coil
reactor
core member
gap
core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP20110809451
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German (de)
English (en)
Other versions
EP2597656A4 (fr
Inventor
Kyoji Zaitsu
Kenichi Inoue
Hiroshi Hashimoto
Hiroyuki Mitani
Hirofumi Hojo
Takashi Morita
Yohei Ikeda
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kobe Steel Ltd
Original Assignee
Kobe Steel Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kobe Steel Ltd filed Critical Kobe Steel Ltd
Publication of EP2597656A1 publication Critical patent/EP2597656A1/fr
Publication of EP2597656A4 publication Critical patent/EP2597656A4/fr
Withdrawn legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F3/14—Constrictions; Gaps, e.g. air-gaps
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F17/045—Fixed inductances of the signal type  with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips

Definitions

  • the present invention relates to a reactor suitable for use in, for example, an electrical circuit and an electronic circuit.
  • Reactors are passive elements employing windings, and for example, are used in various electrical circuits and electronic circuits such as for prevention of harmonic current in a power factor improvement circuit, smoothing of current pulsation in a current source inverter and chopper control, and a step-up of direct-current voltage in a converter.
  • solar batteries have recently been introduced which can directly convert light energy into electric power without emitting carbon dioxide by utilizing a photovoltaic effect.
  • power generation systems using solar batteries have been introduced for residential use.
  • a solar battery power generation system includes, for example, a solar battery module that converts solar energy into electric power, a power conditioner that converts direct-current power generated by the solar battery module into alternating-current power for the purpose of system interconnection, and a power distribution board that distributes the alternating-current power converted by the power conditioner to sites in houses and electric power companies.
  • a reactor is typically employed.
  • hybrid cars and electric cars which can reduce emissions of carbon dioxide have been researched and developed, and have been becoming popular.
  • environment-responsive cars use a booster circuit in a drive control system for a drive motor in order to enhance operating efficiency of the drive motor.
  • a reactor is typically incorporated.
  • Fig. 21 includes structural views of reactors of the related art.
  • Fig. 21(A) illustrates a reactor disclosed in PTL 1
  • Fig. 21(B) illustrates a reactor disclosed in PTL 2.
  • a reactor for the power conditioner in the above-described solar power generation system is disclosed in, for example, PTL 1.
  • a reactor PDA disclosed in PTL 1 includes an annular core 201 formed by two opposing core yokes and a plurality of core legs provided between the core yokes.
  • the core yokes have projections projecting toward the core legs, and gaps are formed between the core legs and the core yokes.
  • Each of the core legs is formed by an integral core block.
  • a ratio A/B of a length A of the projections of the core yokes and an average length B of the magnetic legs in a magnetic path direction is within the range of 0.3 to 8.0, and a coil 202 is wound around the core legs (see Fig.
  • PTL 1 describes that, since the ratio A/B is optimized in the reactor thus structured, it is possible to obtain a high-efficiency reactor in which the increase in copper loss due to leakage flux from the gaps is suppressed, and that a power conditioner having high power conversion efficiency can be produced.
  • a reactor for the booster circuit in the drive control system is disclosed in, for example, PTL 2.
  • a reactor PDB disclosed in PTL 2 includes a coil 301, an inner core 302 provided on an inner side of the coil 301, an outer core 303 provided on an outer side of the coil 301, and end cores 304 and 304 provided at opposite ends of the coil 301.
  • the inner core 302 includes gap materials 302a and core pieces 302b. At least one of the gap materials 302a is formed of a high thermal conductivity material having a thermal conductivity of 100 W/m ⁇ K or more at 25°C.
  • PTL 2 describes that heat radiation performance of the core pieces 302b can be improved by the high thermal conductivity gap material 302a in the reactor thus structured.
  • the reactors for these purposes are required not only to have high efficiency as in PTL 1 and heat radiation efficiency as in PTL 2, but also to have a comparatively high inductance with low levels of noise and loss.
  • noise reduction is important for a reactor used in the power conditioner.
  • the reactor is operated at high frequency, for example, so that noise is above an audible band of about 18 kHz or more, loss is increased by the high frequency. Hence, the above- described loss reduction is important.
  • the present invention has been made in view of the above-described circumstances, and an object of the invention is to provide a reactor that has comparatively high inductance with low levels of loss and noise.
  • a reactor according to the present invention includes a first core section that encases a coil formed by coiling a band-shaped conductor member such that a width direction thereof follows an axial direction, and a second core section provided in a core portion of the coil. Interior surfaces of the first core section facing both end parts of the coil are parallel in a region that at least covers the end parts of the coil, and one end part of the second core section is positioned within an aperture part provided in the first core section, with a gap left between a circumference face of the one end part and a circumference face of the aperture part. For this reason, the reactor of the present invention can have comparatively high inductance with low levels of loss and noise.
  • Fig. 1 includes structural views of a reactor according to a first embodiment.
  • Fig. 1(A) is a longitudinal sectional view including a center axis of a coil 1A, taken along the center axis
  • Fig. 1(B) is a top plan view, as viewed in a direction of the center axis.
  • line A-A is a section line of the longitudinal sectional view of Fig. 1(A) .
  • Fig. 2 explains the relationship between a width W and a thickness t of a conductor member that forms the coil in the reactor of the first embodiment.
  • Fig. 3 explains the relationship between a winding structure of the coil and eddy current loss.
  • Fig. 1(A) is a longitudinal sectional view including a center axis of a coil 1A, taken along the center axis
  • Fig. 1(B) is a top plan view, as viewed in a direction of the center axis.
  • line A-A is a section
  • FIG. 3(A) illustrates a case of a flat-wise winding structure
  • Fig. 3(B) illustrates a case of an edge-wise winding structure
  • Fig. 4 is a graph showing the relationship between a frequency f and loss in the reactor according to the winding structure of the coil.
  • Fig. 5 explains vibration and noise in the reactor of the first embodiment.
  • the reactor according to the first embodiment includes a coil, a first core section that encases the coil, and a second core section provided in a core portion of the coil.
  • the coil is formed by coiling a band-shaped conductor member such that a width direction of the conductor member follows an axial direction of the coil.
  • One interior surface of the first core section, which faces one end part of the coil in the axial direction, and the other interior surface of the first core section, which faces the other end part of the coil in the axial direction, are parallel in a region that at least covers the one end part and the other end part of the coil, and one end part of the second core section is positioned in an aperture part provided in the first core section with a gap left between a circumference face of the one end part and a circumference face of the aperture part.
  • a reactor DA according to the first embodiment thus structured includes a coil 1A, a core member 2A, and a gap member 3.
  • the core member 2A is formed of a material that is isotropic magnetically (e.g., in magnetic permeability), and includes an upper core member 21A and a lower core member 22A.
  • the upper core member 21A includes a platelike upper end core member 21a having a predetermined thickness and shaped like a polygon, a hexagon in the example of Fig. 1 , and a cylindrical side wall core member 21b having a predetermined thickness and extending from an outer peripheral edge of the upper end core member 21a in a substantially perpendicular direction.
  • a transverse section of the cylindrical side wall core member 21b taken in a direction perpendicular to an axial direction is hexagonal in outline (outer shape) because the upper end core member 21a is hexagonal, in the example of Fig. 1 .
  • a circular aperture is provided in the hexagon.
  • the upper end core member 21a has an aperture part APA serving as a through opening.
  • the aperture part APA is a circular hole having a predetermined diameter and centered on the center (geometrical center of gravity) of the upper end core member 21a.
  • the lower core member 22A includes a platelike lower end core member 22a having a predetermined thickness and shaped like the same polygon as the upper end core member 21a, a hexagon in the example of Fig. 1 , and a convex part core member 22b provided on one principal surface of the lower end core member 22a.
  • the convex part core member 22b is shaped like a column centered on the center (geometrical center of gravity) of the lower end core member 22a and having a predetermined outer diameter. The outer diameter gradually increases from a middle portion in the axial direction toward the lower end core member 22a, and a circumference face of the column is tapered.
  • the convex part core member 22b is solid in the example of Fig. 1 , it may have an internal cavity. Further, heat radiation performance of the reactor may be enhanced by passing a predetermined fluid, such as air or water, through the cavity.
  • the core member 2A is formed by coupling (connecting) an end of the side wall core member 21b of the upper core member 21A thus structured to a peripheral edge of the lower end core member 22a of the lower core member 22A in a substantially gapless manner.
  • a space for receiving the coil 1A is thereby formed between the upper end core member 21a and the lower end core member 22a and between the side wall core member 21b and the convex part core member 22b.
  • a distal end part of the convex part core member 22b is inserted in the aperture part APA of the upper end core member 21a, and is positioned in the aperture part APA with a gap GA left between a circumference face (outer circumference face) of the distal end part of the convex part core member 22b and a circumference face (inner circumference face) of the aperture part APA. That is, the diameter of the aperture part APA is larger than the diameter of the convex part core member 22b.
  • the distal end part of the convex part core member 22b slightly protrudes outward from an outer surface of the upper end core member 21b.
  • the upper end core member 21a and the side wall core member 21b in the upper core member 21A and the lower end core member 22a in the lower core member 22A correspond to an example of the above-described first core section containing the coil 1A
  • the convex part core member 22b in the lower core member 22A corresponds to an example of the above-described second core section positioned in the core portion of the coil 1A.
  • the first core section (the upper end core member 21a, the side wall core member 21b, and the lower end core member 22a in the example of Fig. 1 ) serves to reduce magnetic flux leaking outside, and the maximum relative magnetic permeability thereof is designed, for example, on the basis of the allowed magnitude of leakage flux of the reactor DA that is defined by the specifications.
  • the maximum relative magnetic permeability of the first core section is, for example, about 100 or more for the reactor DA suitable for use in a power conditioner of a solar battery power generation system.
  • the maximum relative magnetic permeability of the second core section (the convex part core member 22b in the example of Fig. 1 ) is designed, for example, on the basis of the magnitude of inductance, which is required for the reactor DA, specified by the specifications because the maximum relative magnetic permeability has an influence on the inductance of the reactor DA.
  • the power conditioner of the solar battery power generation system requires stability of an inductance characteristic in that the change in inductance is small with respect to the change in current so that operation is stably performed even when the current changes. Since the change in current is steep when the inductance is comparatively low, it is better that the inductance is comparatively high. However, as the inductance increases, the size of the reactor DA increases.
  • the average value of current flowing through the reactor DA is about 20 A, and is about 30 A at most.
  • the inductance should be about 1 mH around the current value of 20 A, in consideration of the balance therebetween, and the maximum relative magnetic permeability of the second core section is set in consideration of a gap effect and so on.
  • the core member 2A is molded from soft magnetic powder alone or a mixture of soft magnetic powder and nonmagnetic power.
  • the mixture ratio of soft magnetic powder and nonmagnetic powder can be comparatively easily adjusted.
  • a desired magnetic characteristic of the core member 2A can be realized easily.
  • the core member 2A is formed of soft magnetic powder alone or the mixture of soft magnetic powder and nonmagnetic powder, it can be molded in various shapes, and can be easily molded in a desired shape.
  • the upper core member 21A and the lower core member 22A are preferably formed of the same raw material.
  • This soft magnetic power is ferromagnetic metal powder, and more specifically, examples of the soft magnetic powder are pure iron powder, iron-base alloy powder (e.g., an Fe-Al alloy, an Fe-Si alloy, sendust, or a permalloy), amorphous powder, and iron powder whose surface is covered with an electrical insulating coating such as a phosphorylated coating.
  • These soft magnetic powders can be produced, for example, by a method of performing microparticulation using atomization or a method of reducing iron oxide after pulverization.
  • the upper core member 21A and the lower core member 22A are members that have a predetermined magnetic flux density to relative magnetic permeability characteristic and that are molded from a mixture of iron powder serving as soft magnetic powder and resin serving as nonmagnetic powder using a known common method to have a predetermined density.
  • the magnetic flux density to relative magnetic permeability characteristic refers to the change in relative magnetic permeability with respect to the change in magnetic flux density.
  • the upper end core member 21a and the side wall core member 21b in the upper core member 21A are integrally formed in the example of Fig. 1 , they may be separately formed and then coupled (connected) to each other.
  • the lower end core member 22a and the convex part core member 22b in the lower core member 22A are integrally formed in the example of Fig. 1 , they may be separately formed and then coupled (connected) to each other.
  • the core member 2A is divided into the upper core member 21A and the lower core member 22A in the example of Fig. 1 , it may be arbitrarily divided into members.
  • the coil 1A is formed by coiling a long conductor member in a predetermined number of turns, and is energized to generate a magnetic field.
  • the coil 1A is formed by coiling a band-shaped conductor member such that the width direction of the conductor member follows the axial direction of the coil 1A.
  • the coil 1A is positioned in the above-described space formed between the upper end core member 21a and the lower end core member 22a and between the side wall core member 21b and the convex part core member 22b, and the convex part core member 22b is positioned in the core portion of the coil 1A to penetrate through the coil 1A.
  • the reactor DA of this embodiment is a so-called pot type reactor in which the cored coil 1A is received in the internal space of the core member 2A. Further, in the reactor DA of the embodiment, one interior surface of the upper end core member 21a, which faces one end part of the coil 1A in the axial direction, and the other interior surface of the lower end core portion 22a, which faces the other end part of the coil 1A in the axial direction, are parallel to each other in a region that at least covers the one end part and the other end part of the coil 1A.
  • band-shaped refers to a shape such that the width W is larger than the thickness t, as illustrated in Fig. 2 . That is, the width W and the thickness t have a relationship that W > t (W/t > 1). In this way, the coil 1A of the embodiment has a so-called flat-wise winding structure.
  • the reactor DA including the coil 1A having the flat-wise winding structure in which the conductor member is coiled to have layers stacked in the radial direction ( Figs. 1 and 3(A) ), and a reactor DH including a coil 1H having an edge-wise winding structure in which a conductor member is coiled to have layers stacked in the axial direction ( Fig. 3(B) ).
  • eddy current occurs in a plane (orthogonal plane) perpendicular to lines of magnetic force because the coil is formed of a conductor, and this causes loss.
  • the magnitude of the eddy current is proportional to the area intersecting the lines of magnetic force, that is, the area of a continuous plane perpendicular to the lines of magnetic force. Since the lines of magnetic force extend in the axial direction in the coil, as illustrated in Figs. 3(A) and 3(B) , the eddy current is proportional to the area of a plane of the conductor of the coil in the radial direction orthogonal to the axial direction.
  • the loss depends on the frequency of energizing current and increases as the frequency increases.
  • the conductor member is stacked in the axial direction in the edge-wise winding structure, as illustrated in Fig. 3(B)
  • the conductor member is continuous in a state in which the width direction nearly coincides with the axial direction in the flat-wise winding structure, as illustrated in Figs. 3(A) and 1 .
  • heat generated in the coil is more effectively transferred to the core in the flat-wise winding structure than in the edge-wise winding structure.
  • the reactor DA thus including the coil 1A having the flat-wise winding structure is superior to the reactor DH including the coil 1H having the edge-wise winding structure in terms of loss and heat transfer.
  • a gap formed between the coil 1A and the first core section (upper end core member 21a, side wall core member 21b, and lower end core member 22a) in the reactor DA may be filled with a heat transfer material 6 that comparatively properly transfers heat, as shown by broken lines in Fig. 1 .
  • heat produced in the coil 1A can be transferred via the heat transfer material to the first core section surrounding the coil 1A, and this can improve heat radiation performance.
  • the heat transfer material a polymeric material having comparatively high thermal conductivity (polymeric material having comparatively high conductivity) can be given as an example.
  • the polymeric material is epoxy resin having high adhesiveness.
  • the heat transfer material may be an insulating material such as BN ceramic (boron nitride ceramic), and filling may be performed with a compound. Such a heat transfer material can also improve insulation performance.
  • the conductor member is band-shaped in the flat-wise winding structure, as described above. That is, as illustrated in Fig. 2(A) , the reactor DA is formed of the conductor member forming the coil 1A such that the conductor member has a rectangular cross section in which the width W is greater than the thickness t (the length of the conductor member in the radial direction).
  • the area in the radial direction is smaller than in a reactor formed by a conductor member having a rectangular cross section in which the thickness t is greater than the width W.
  • eddy current loss can be reduced for a reason similar to the above-described reason why the coil 1A having the flat-wise winding structure is superior to the coil DH having the edge-wise winding structure in terms of loss.
  • a ratio t/W of the width W to the thickness t in the conductor member is 1/10 or less (t/W ⁇ 1/10, 10t ⁇ W)
  • the occurrence of eddy current loss can be significantly reduced.
  • one interior surface of the first core section (upper end core member 21a), which faces one end part of the coil 1A in the axial direction, and the other interior surface of the first core section (lower end core member 22a), which faces the other end part of the coil 1A in the axial direction, are parallel to each other in the region that at least covers the one end part and the other end part of the coil 1A.
  • the reactor DA is structured such that the upper end lower interior wall surfaces (upper and lower wall surfaces) of the first core section, which face the upper and lower end faces of the coil 1A, are parallel in the region that at least covers the end parts of the coil 1A.
  • a distance at a position on the innermost peripheral side of the coil 1A (innermost peripheral position), of distances between the upper wall surface and the lower wall surface of the first core section, is taken as L1
  • a distance at a position on the outermost peripheral side of the coil 1A (outermost peripheral position) is taken as L2
  • the average value of the distances from the innermost peripheral position to the outermost peripheral position is taken as L3
  • the average value L3 refers to an average value of distances at a plurality of positions spaced at a predetermined interval between the innermost peripheral position and the outermost peripheral position.
  • the present inventor verified the distribution of lines of magnetic flux while variously changing the parallelism. For example, when the parallelism is 1/100, the lines of magnetic flux passing through the coil 1 are parallel to the axial direction. In contrast, when the parallelism is -1/10 or 1/10, the lines of magnetic flux passing through the coil 1 are not parallel to the axial direction. According to this verification, it is preferable that the absolute value of the parallelism should be 1/50 or less in order for the lines of magnetic flux passing through the coil 1A to be parallel.
  • Unillustrated terminals are connected to opposite ends of the coil 1A to feed power from the outside to the coil 1A. These terminals lead to the outside via the first core section, for example, via through holes provided in the upper end core member 21a.
  • the gap member 3 is a member to be inserted in the gap GA having a predetermined distance (gap length) formed between the circumference face (outer circumference face) of the distal end part of the convex part core member 22b and the circumference face (inner circumference face) of the aperture part APA.
  • the gap member 3 maintains the gap length, and fixes the upper end core member 21a of the upper core member 21A and the convex part core member 22b of the lower core member 22A.
  • the gap member 3 includes a cap portion doughnut-shaped in plan view, and a cylindrical gap portion hanging from a lower surface of the cap portion to be inserted in the gap GA.
  • a longitudinal section of the gap member 3 taken perpendicularly to the circumferential direction is substantially T-shaped.
  • Such a gap member 3 is formed of epoxy resin or alumina for example. By adjusting the gap length, the change in inductance within a desired current range can be controlled.
  • the gap length changes according to the manufacturing accuracy of the material to be inserted in the gaps and an application condition of adhesive.
  • the change value is taken as ⁇ n and the designed value is taken as g, ⁇ (g+ ⁇ n ) (were ⁇ sums values of n from 1 to the gap number).
  • the gap number is decreased to increase the accuracy of the gap length in the reactors PDA and PDB having the conventional structures, the gap length needs to be increased to obtain equivalent characteristics. For this reason, leakage flux from the gap increases, and the leakage flux passes through the conductor of the coil, so that eddy current loss increases. As a result, the efficiency of the reactor is reduced.
  • the convex part core member 22b is inserted in the aperture part APA of the upper end core member 21a, and the gap GA is formed between the circumference face (outer circumference face) of the distal end part of the convex part core member 22b and the circumference face (inner circumference face) of the aperture part APA.
  • the gap length is balanced out on both sides of the center (axial center) (g+ ⁇ , g- ⁇ ), as illustrated in Fig. 1 .
  • the inductance of the reactor DA of the embodiment is constant.
  • the core member 2A is formed by compacting iron powder, product-to-product variations in inductance are reduced or are not caused because manufacturing accuracies of the diameter of the aperture part APA of the upper end core member 21a and the diameter of the convex part core member 22b nearly coincide with the accuracy of a mold.
  • the reactor DA thus structured can reduce vibration and noise.
  • the Poisson's ratio ⁇ is about 0.5 for liquid and about 0.3 for solid.
  • the displacement amounts of the reactors can be compared by comparing these proportionality coefficients ([ ⁇ xa 4 /h 3 ], [ ⁇ 1- ⁇ +(1+ ⁇ ) ⁇ a 2 /b 2 ] ⁇ b 3 /(a 2 -b 2 ) ⁇ ]. Accordingly, when a:b:h is 2:1:0.5 as a typical shape, the deflection factor ⁇ is 0.1 to 0.35, and the Poisson's ratio ⁇ is 0.3, the proportionality coefficient is estimated at 13 to 45 in the reactor PDB having the conventional structure of Fig. 21(B) .
  • the proportionality coefficient is 1.5 in the reactor DA of the embodiment.
  • the proportionality coefficient of the reactor DA of the embodiment is about 3 to 12% of the proportionality coefficient of the reactor PDB having the conventional structure of Fig. 21(B) .
  • the displacement amount is smaller than in the reactor PDB having the conventional structure of Fig. 21(B) . As a result, noise is reduced.
  • the core and the gap member cannot be combined in a state in which the surface of the core and the surface of the gap member opposing the surface of the core are completely flat, and they need to be brought into tight contact with each other by a comparatively soft plugging material such as adhesive.
  • the gap length is changed by loosening and rattling due to this soft plugging material, and this causes vibration and noise.
  • vibration of the core is about several micrometers.
  • the convex part core member 22b is inserted in the aperture part APA of the upper end core member 21a and the gap GA is formed between the circumference face (outer circumference face) at the distal end part of the convex part core member 22b and the circumference face (inner circumference face) of the aperture part APA.
  • the average of the annular gap GA is constant over the entire circumference, and therefore, there is no need to accurately manage the gap length of the gap GA. Therefore, the above-described soft plugging material is unnecessary, and noise resulting from gap management during assembly in the reactors PDA and PDB having the conventional structures is reduced or does not occur.
  • This reactor DA of the embodiment can be produced through the following steps. First, a band-shaped (ribbon-shaped) long conductor member insulatively covered with an insulating material and having a predetermined thickness t is prepared, and the conductor member is wound around a convex part core member 22b in a predetermined number of turns. Alternatively, the conductor member is wound in a predetermined number of turns from a position apart a predetermined radius from the center (axial center) to form an air-cored coil, and the air-cored coil is mounted on a lower core member 22A such that the convex part core member 22b is positioned in a core portion of the air-cored coil.
  • a coil 1A having a pancake structure which has the convex part core member 22b in the center portion (core portion) and which is formed by coiling the band-shaped long conductor member, which is superposed with the insulating material disposed therebetween, in a predetermined number of turns.
  • an end of a side wall core member 21b of an upper core member 21A is coupled (connected) to a peripheral edge of a lower end core member 22a of the lower core member 22A in a substantially gapless manner.
  • a gap member 3 is mounted in a gap GA.
  • a reactor DA illustrated in Fig. 1 is produced.
  • the coil 1A is formed by coiling the band-shaped conductor member such that the width direction of the conductor member follows the axial direction of the coil 1A, and the inner wall surface of the upper end core member 21a in the upper core member 21A, which faces one end part of the coil 1A in the axial direction, and the inner wall surface of the lower end core member 22a in the lower core member 22A, which faces the other end part of the coil 1A in the axial direction, are parallel to each other in the region that at least covers the one end part and the other end part of the coil 1A.
  • the reactor DA thus structured can reduce eddy current loss, as described above.
  • the reactor DA having the above-described structure is a so-called pot type reactor including the upper core member 21A and the lower core member 22A that encase the coil 1A, and the coil 1A has the convex part core member 22b of the lower core member 22A in its core portion.
  • the reactor DA can have comparatively high inductance.
  • one end part (distal end part) of the convex part core member 22b in the lower core member 22A is positioned in the aperture part APA in the upper end core member 21a of the upper core member 21A with the gap GA left between the circumference face of the one end part and the circumference face of the aperture part APA.
  • the change in inductance within a desired current range can be controlled by adjusting the distance of the gap GA (gap length).
  • the gap length is defined by the difference between the diameter (inner diameter) of the aperture part APA and the diameter (outer diameter) of the one end part of the convex part core member 22b.
  • the reactor DA thus structured can suppress the change in the gap length due to misalignment between the center of the aperture part APA and the center of the one end part of the convex part core member 22b. For this reason, the reactor DA thus structured can reduce product-to-product variations in gap length (differences among individual reactors). As a result, the reactor DA thus structured can also reduce product-to-product variations in inductance.
  • both electromagnetic attractive force and magnetostrictive expansion are produced in the radial direction in the gap GA. Since the reactor DA thus structured has high mechanical structural rigidity in the radial direction, it can reduce vibration and noise. As measures against noise, even when the reactor is operated at high frequency, for example, so that noise is above an audible band of about 18 kHz or more, since the eddy current loss is reduced, as described above, loss can also be reduced.
  • the reactor DA thus structured can have comparatively high inductance with low levels of loss and noise.
  • Fig. 7 shows a magnetic-field analysis result when low inductance is obtained in a large current range in the reactor DA thus structured.
  • compacted iron powder having a magnetic characteristic shown by a solid line in Fig. 6 was used in the core member 2A.
  • a magnetic characteristic of a directional electromagnetic steel sheet is also shown by a broken line.
  • Fig. 6 shows a magnetic field to magnetic flux density characteristic of the core used in the reactor of the first embodiment.
  • the horizontal axis indicates the magnetic field expressed in the unit of A/m
  • the vertical axis indicates the magnetic flux density expressed in the unit of T.
  • Fig. 7 illustrates lines of magnetic flux in the reactor of the first embodiment.
  • the reactor D when the reactor D adopts the structure of the embodiment and below-described structures, it can obtain inductance performances suitable for various kinds applications, for example, as illustrated in Fig. 16 described below.
  • Fig. 8 is a cross-sectional structural view of a reactor according to a second embodiment.
  • Fig. 9 illustrates lines of magnetic flux in the reactor of the second embodiment.
  • Fig. 10 illustrates a comparison between the lines of magnetic flux in the reactor of the first embodiment and the lines of magnetic flux in the reactor of the second embodiment.
  • a reactor DB of the second embodiment the other end part of the second core section is coupled to the first core section, and the first core section further includes a projection extending from a peripheral edge that forms the aperture part into the first core.
  • a reactor DB of the second embodiment includes, for example, a coil 1A, a core member 2B, and a gap member 3, as illustrated in Fig. 8 . Since the coil 1A and the gap member 3 in the reactor DB of the second embodiment are similar to the coil 1A and the gap member 3 in the reactor DA of the first embodiment, descriptions thereof are skipped.
  • the core member 2B is formed of a material that is isotropic magnetically (e.g., in magnetic permeability), and includes an upper core member 21B and a lower core member 22A. Since the lower core member 22A in the reactor DB of the second embodiment is similar to the lower core member 22A in the reactor DA of the first embodiment, a description thereof is skipped.
  • the upper core member 21B includes a platelike upper end core member 21a having a predetermined thickness and shaped like a polygon, for example, a hexagon, and a cylindrical side wall core member 21b having a predetermined thickness and extending from an outer peripheral edge of the upper end core member 21a in a substantially perpendicular direction.
  • the upper end core member 21a has an aperture part APA serving as a through aperture. Since the upper end core member 21a and the side wall core member 21b in the reactor DB of the second embodiment are similar to the upper end core member 21a and the side wall core member 21b in the reactor DA of the first embodiment, descriptions thereof are skipped.
  • the upper core member 21B further includes a projection 21c extending from a peripheral edge that forms the aperture part APA into the first core.
  • the reactor DB of the second embodiment having such a structure, even when the reactor DB is designed to have high inductance in a comparatively small current range by increasing the number of turns of the coil 1A, as illustrated in Fig. 9 , the direction of lines of magnetic flux passing through the coil 1A can be made close to a direction parallel to the axial direction of the coil 1A, and eddy current loss can be reduced for the above-described reason. This can be easily understood with reference to Fig.
  • Fig. 11 is a cross-sectional structural view of a reactor according to a third embodiment.
  • Fig. 12 illustrates lines of magnetic flux in the reactor of the third embodiment.
  • a reactor DC in a reactor DC according to the third embodiment, the other end part of the second core section is positioned in a second aperture part provided in the first core section with a second gap left between a circumference face of the other end part and a circumference face of the second aperture part.
  • a reactor DC of the third embodiment includes a coil 1A, a core member 2C, and gap members 3 and 4. Since the coil 1A and the gap member 3 in the reactor DC of the third embodiment are similar to the coil 1A and the gap member 3 in the reactor DA of the first embodiment, descriptions thereof are skipped.
  • the core member 2C is formed of a material that is isotropic magnetically (e.g., in magnetic permeability), and includes an upper core member 21A, a lower core member 22B, and a center core member 23A. Since the upper core member 21A in the reactor DC of the third embodiment is similar to the upper core member 21A in the reactor DA of the first embodiment, a description thereof is skipped.
  • the lower core member 22B is similar to an upper end core member 21a in the upper core member 21A, and is a platelike member having the same polygonal shape as the shape of the upper end core member 21a, for example, a hexagonal shape.
  • the lower core member 22B has an aperture part APB serving as a through aperture similar to an aperture part APA of the upper end core member 21a.
  • the aperture part APB is a circular hole having a predetermined diameter and centered on a center position (geometrical center of gravity) of the lower core member 22B.
  • the center core member 23A is a column having a predetermined outer diameter, similarly to the convex part core member 22b of the first embodiment. While the center core member 23A is solid, it may have an internal cavity. Further, heat radiation performance of the reactor may be enhanced by passing a predetermined fluid, such as air or water, through the cavity.
  • One end part of the center core member 23A is inserted in the aperture part APA of the upper end core member 21a, and is positioned in the aperture part APA with a first gap GAA left between a circumference face (outer circumference face) of the one end part of the center core member 23A and a circumference face (inner circumference face) of the aperture part APA.
  • the other end part of the center core member 23A is inserted in the aperture part APB of the lower core member 22B, and is positioned in the aperture part APB with a second gap GAB left between a circumference face (outer circumference face) of the other end part of the center core member 23A and a circumference face (inner circumference face) of the aperture part APB.
  • the upper core member 21A and the lower core member 22B correspond to an example of the first core section encasing the coil 1A
  • the center core member 23A corresponds to an example of the second core section provided in the core portion of the coil 1A.
  • the gap member 3 is a member to be inserted in the gap GAA with a predetermined distance (gap length) formed between the circumference face (outer circumference face) of the one end part of the center core member 23A and the circumference face (inner circumference face) of the aperture part APA.
  • the gap member 4 is a member to be inserted in the gap GAB with a predetermined distance (gap length) formed between the circumference face (outer circumference face) of the other end part of the center core member 23A and the circumference face (inner circumference face) of the aperture part APB.
  • the gap member 3 maintains the gap length, and fixes the upper end core member 21a of the upper core member 21A and the center core member 23A.
  • the gap member 4 maintains the gap length, and fixes the lower core member 22B and the center core member 23A.
  • Each of the gap members 3 and 4 includes a cap portion doughnut-shaped in plan view, and a cylindrical gap portion hanging from a lower surface of the cap member to be inserted in the gap GA.
  • a longitudinal section of the gap members 3 and 4 perpendicular to the circumferential direction is substantially T-shaped.
  • the gap members 3 and 4 are formed of epoxy resin or alumina.
  • the coil 1A is located in a space formed between the upper end core member 21a and the lower core member 22B and between a side wall core member 21b and the center core member 23A, and the center core member 23A is located in the core portion of the coil 1A to penetrate through the coil 1A.
  • the reactor DC of the third embodiment thus structured includes a plurality of gaps GA, that is, the first gap GAA and the second gap GAB, the gaps GA can be provided separately. For this reason, as shown by comparison of Fig. 7 and Fig. 12 , the reactor DC of the third embodiment thus structured can reduce magnetic flux leaking outside more than the reactor DA of the first embodiment. As a result, the reactor DC can minimize the influence of leakage flux on peripheral devices provided around the reactor DC.
  • Fig. 13 includes structural views of reactors and mount members according to a modification of the third embodiment.
  • Fig. 13(A) is an overall perspective view of a first mode of the modification
  • Fig. 13(B) is a cross-sectional view of the first mode of the modification
  • Fig. 13(C) is a bottom view of the first mode of the modification, as viewed from a mount member side
  • Fig. 13(D) is a schematic cross-sectional view (schematic view of Fig. 13(C) ), schematically illustrating a cross-section of the first mode of the modification
  • Fig. 13(E) is a schematic cross-sectional view schematically illustrating a cross section of a second mode of the modification.
  • the reactor generates heat through various losses.
  • the reactor is fixed in contact with a flat radiator plate formed of a good thermal conductivity metal material, which has comparatively low thermal conductivity, for the purpose of heat transfer and heat radiation.
  • the metal material is copper or an alloy thereof, iron or an alloy thereof, or aluminum and an alloy thereof.
  • a radiator plate 6A has one or a plurality of slit holes 6a in a mount surface on which a reactor DC' is to be mounted.
  • the longitudinal direction of the slit holes 6a intersects a second gap GAB in plan view, as viewed in the axial direction of a coil 1A, and the slit holes 6a penetrate through the radiator plate 6A.
  • a radiator plate 6B has one or a plurality of slit grooves 6b on a mount surface on which a reactor DC' is to be mounted.
  • the longitudinal direction of the slit grooves 6b intersects a second gap GAB in the longitudinal direction in plan view, as viewed in the axial direction of a coil 1A, and the slit grooves 6b have a depth greater than or equal to the distance of the second gap GAB.
  • a plurality of slit holes 6a and 6b are radially arranged in the radial direction and at regular intervals in the circumferential direction on the mount surface on which the reactor DC' is to be mounted in a manner such that the longitudinal direction thereof intersects the second gap GAB.
  • the reactor DC' does not include the gap member 3 and 4, and is fastened to the radiator plate 6A or 6B by bolts 7 via through holes provided in a core member 2C'. Further, while the overall shape of the core member 2C' is the same as that of the core member 2C, the core member 2C' is formed by two upper and lower members of the same shape.
  • the reactor DC' thus structured since the slit holes 6a are provided in the radiator plate 6A, or since the slit grooves 6b are provided in the radiator plate 6B, the flow of the above-described eddy current is prevented by the slit holes 6a or the slit grooves 6b. Therefore, the reactor DC' thus structured can radiate heat without causing any power loss and any inductance change.
  • Fig. 14 is a cross-sectional structural view of a reactor according to a fourth embodiment.
  • Fig. 15 illustrates lines of magnetic flux in the reactor of the fourth embodiment.
  • a reactor DC in a reactor DC according to the fourth embodiment, the other end part of the second core section is provided with a third gap from the other interior surface of the first core section.
  • a reactor DD of the fourth embodiment includes a coil 1A, a core member 2D, and a gap member 3. Since the coil 1A and the gap member 3 in the reactor DD of the fourth embodiment are similar to the coil 1A and the gap member 3 in the reactor DA of the first embodiment, descriptions thereof are skipped.
  • the core member 2D is formed of a material that is isotropic magnetically (e.g., in magnetic permeability), and includes an upper core member 21A, a lower core member 22C, and a center core member 23B. Since the upper core member 21A in the rector DD of the fourth embodiment is similar to the upper core member 21A. in the reactor DA of the first embodiment, a description thereof is skipped.
  • the lower core member 22C is a platelike member having a predetermined thickness and the same polygonal shape as the outer shape of an upper end core member 21a, for example, a hexagonal shape.
  • the center core member 23B is a column having a predetermined outer diameter, similarly to the convex part core member 22b in the first embodiment. While the center core member 23B is solid, it may have an internal cavity. Further, heat radiation efficiency of the reactor may be enhanced by passing a predetermined fluid, such as air or water, through the cavity.
  • One end part of the center core member 23B is inserted in an aperture part APA of the upper end core member 21a, and is positioned in the aperture part APA with a first gap GAA left between a circumference face (outer circumference face) of the one end part of the center core member 23B and a circumference face (inner circumference face) of the aperture part APA.
  • the other end part of the center core member 23B is provided with a third gap GAC from an interior surface of the lower core member 22C.
  • a gap member of epoxy resin or alumina (unillustrated) is inserted in the third gap GAC.
  • a peripheral edge of the other end part of the center core member 23B may be chamfered, for example, by R-chamfering or C-chamfering. In the example illustrated in Fig. 14 , the peripheral edge is subjected to R-chamfering.
  • the upper core member 21A and the lower core member 22C correspond to an example of the first core section encasing the coil 1A
  • the center core member 23B corresponds to an example of the second core section provided in the core portion of the coil 1A.
  • the coil 1A is provided in a space formed between the upper end core member 21a and the lower core member 22B and between a side wall core member 21b and the center core member 23B, and the center core member 23B is provided in the core portion of the coil 1A.
  • the reactor DD of the fourth embodiment thus structured includes a plurality of gaps GA, that is, the first gap GAA and the third gap GAC, and therefore, the gaps GA can be provided separately.
  • the reactor DC of the fourth embodiment thus structured can reduce more leakage magnetic flux leaking outside than the reactor DA of the first embodiment. As a result, the influence of leakage flux on peripheral devices provided around the reactor DD can be minimized.
  • Fig. 16 shows inductance characteristics of the reactors DA, DB, DC, and DD according to the first to fourth embodiments.
  • the horizontal axis is a logarithmic scale indicating the current expressed in the unit of A
  • the vertical axis indicates the inductance expressed in the unit of ⁇ H.
  • ⁇ , O, ⁇ , and ⁇ indicate the inductance characteristics of the reactors DA, DB, DC, and DD of the first to fourth embodiments, respectively.
  • the inductance hardly changes and is stable within a comparatively large current range, in the range of about 20 A to about 200 A in the example of Fig. 16 .
  • the change in inductance is smaller and the inductance is more stable, which is preferable.
  • the change in inductance is even smaller, and the inductance is even more stable, which is preferable.
  • the reactors DA, DC, and DD of the first, third, and fourth embodiments are of a large current type.
  • the inductance hardly changes and is stable within the range of a comparatively small current range, within the range of about 5 A to about 25 A in the example of Fig. 16 . Particularly within the range of about 5 A to about 20 A, the change in inductance is smaller and the inductance is more stable, which is preferable.
  • Fig. 17 is a cross-sectional structural view of a reactor according to a fifth embodiment. While the coil 1A is a single coil having a pancake structure in the reactors DA, DB, DC, and DD of the first to fourth embodiments, a reactor DE according to the fifth embodiment uses a coil 1B formed by a plurality of sub-coils stacked in the axial direction, instead of the coil 1A in the reactors DA, DB, DC, and DD of the first to fourth embodiments.
  • Fig. 17 illustrates the reactor DE of the fifth embodiment that employs the core member 2B in the reactor DB of the second embodiment.
  • the reactor DE of the fifth embodiment includes the coil 1B, the core member 2B, and a gap member 3. Since the core member 2B and the gap member 3 in the reactor DE of the fifth embodiment are similar to the core member 2B and the gap member 3 in the reactor DB of the second embodiment, descriptions thereof are skipped.
  • the coil 1B includes a plurality of sub-coils stacked in the axial direction, that is, two sub-coils 11a and 11b in the example illustrated in Fig. 17 .
  • each of the sub-coils 11a and 11b is formed by coiling a band-shaped conductor member such that the width direction of the conductor member follows the axial direction of the sub-coil 11a or 11b (coil 1B).
  • Fig. 18 is a cross-sectional structural view of a reactor according to a sixth embodiment. While the coil 1A is a single coil having a pancake structure in the reactors DA, DB, DC, and DD of the first to fourth embodiments, a reactor DF according to the sixth embodiment employs a coil 1C formed by a plurality of sub-coils stacked in the radial direction, instead of the coil 1A in the reactors DA, DB, DC, and DD of the first to fourth embodiments.
  • Fig. 18 illustrates the reactor DF of the sixth embodiment that employs the core member 2B in the reactor DB of the second embodiment. In the example illustrated in Fig.
  • the reactor DF of the sixth embodiment includes the coil 1C, the core member 2B, and a gap member 3. Since the core member 2B and the gap member 3 in the reactor DF of the sixth embodiment are similar to the core member 2B and the gap member 3 in the reactor DB of the second embodiment, descriptions thereof are skipped.
  • the coil 1C includes a plurality of sub-coils stacked in the radial direction, that is, two sub-coils 12a and 12b in the example of Fig. 18 .
  • each of the sub-coils 12a and 12b is formed by coiling a band-shaped conductor member such that the width direction of the conductor member follows the axial direction of the sub-coil 12a or 12b (coil 1C).
  • the sub-coil 12a is located on a relatively inner side
  • the sub-coil 12b is located on a relatively outer side.
  • Fig. 19 is a cross-sectional structural view of a reactor according to a seventh embodiment.
  • a reactor DG according to the seventh embodiment employs a coil 1D formed by coiling a plurality of band-shaped conductor members to form layers with insulating layers being disposed therebetween, instead of the coil 1A in the reactors DA, DB, DC, and DD of the first to fourth embodiments.
  • Fig. 19 illustrates the reactor DG of the seventh embodiment that employs the core member 2B in the reactor DB of the second embodiment.
  • the reactor DG of the seventh embodiment includes the coil 1D, the core member 2B, and a gap member 3. Since the core member 2B and the gap member 3 in the reactor DG of the seventh embodiment are similar to the core member 2B and the gap member 3 in the reactor DB of the second embodiment, descriptions thereof are skipped.
  • the coil 1D is formed by coiling a plurality of band-shaped conductor members 13 such that the width direction of the conductor members 13 follows the axial direction of the coil 1D and such that conductor members 13 form layers stacked in the radial direction with insulating layers being disposed therebetween.
  • each of the reactors DE, DF, and DG of the fifth to seventh embodiments includes a plurality of sub-coils, it can be diverted to a transformer by changing connections of the sub-coils so that at least one of the sub-coils serves as a primary coil and at least one of the other sub-coils serves as a secondary coil.
  • Such a transformer diverted from any of the reactors DE, DF, and DG of the fifth to seventh embodiments can have comparatively high mutual inductance with low levels of loss and noise.
  • such a transformer diverted from any of the reactors DE, DF, and DG of the fifth to seventh embodiments can be used as a so-called insulation transformer, as shown by an equivalent circuit illustrated in Fig. 20(A) , or can be used as a so-called choke transformer (filter), as shown by equivalent circuits illustrated in Figs. 20(B) and 20(C).
  • Fig. 20(B) illustrates a common mode
  • Fig. 20(C) illustrates a differential mode.
  • the thickness t of the conductor member in the coils 1A to 1D is less than or equal to the skin depth with respect to the frequency of alternating-current power to be fed to the reactors DA to DG.
  • the reactors DA to DG thus structured can further reduce eddy current loss.
  • current flowing through the coil flows only in a region corresponding to the skin depth ⁇ , but does not uniformly flow in the entire section of the conductor. Therefore, eddy current loss can be reduced by setting the thickness t of the conductor member to be less than or equal to the skin depth ⁇ .
  • ⁇ represents the angular frequency of the alternating-current power
  • ⁇ represents the magnetic permeability of the conductor member
  • p represents the electrical conductivity of the conductor member
  • the skin depth ⁇ is generally equal to (2/ ⁇ ) 1/2 .
  • the core members 2A to 2D have magnetic isotropy and are formed of soft magnetic powder in the reactors DA to DG of the above-described embodiments
  • the core members 2A to 2D may be ferrite cores having magnetic isotropy. Such ferrite cores can comparatively easily realize a desired magnetic characteristic, and can be comparatively easily molded in a desired shape.
  • a reactor includes a coil, a first core section encasing the coil, and a second core section provided in a core portion of the coil.
  • the coil is formed by coiling a band-shaped conductor member such that a width direction of the conductor member follows an axial direction of the coil.
  • One interior surface of the first core section, which faces one end part of the coil in the axial direction, and the other interior surface of the first core section, which faces the other end part of the coil in the axial direction, are parallel in a region that at least covers the one end part and the other end part of the coil.
  • One end part of the second core section is positioned within an aperture part provided in the first core section, with a gap left between a circumference face of the one end part and a circumference face of the aperture part.
  • the coil is formed by coiling the band-shaped conductor member such that the width direction of the conductor member follows the axial direction of the coil, and one interior surface of the first core section, which faces one end part of the coil in the axial direction, and the other interior surface of the first core section, which faces the other end part of the coil in the axial direction, are parallel in the region that at least covers the one end part and the other end part of the coil. For this reason, since the width direction of the band-shaped conductor member follows the direction of magnetic flux in the coil, the reactor thus structured can reduce eddy current loss.
  • the reactor thus structured is a so-called pot type reactor including the first core section that encases the coil, and the coil has the second core section in its core portion.
  • the reactor can have comparatively high inductance.
  • the one end part of the second core section is positioned in the aperture part of the first core section with the gap left between the interior surface of the one end part and the interior surface of the aperture part.
  • the change in inductance within a desired current range can be controlled by adjusting the distance of the gap (gap length).
  • the gap length is defined by the difference between the diameter (inner diameter) of the aperture part of the first core section and the diameter (outer diameter) of the one end part of the second core section when the aperture part is circular and the one end part is also circular
  • the reactor thus structured can suppress the change in the gap length due to misalignment between the center of the aperture part and the center of the one end part. For this reason, in the reactor thus structured, product-to-product variations in the gap length (differences among individual reactors) are reduced. As a result, the reactor thus structured can also reduce product-to-product variations in inductance.
  • the reactor thus structured can reduce vibration and noise because it has high mechanical rigidity in the radial direction.
  • the reactor is operated at high frequency, for example, so that noise is above an audible band of about 18 kHz or more, since the eddy current loss is reduced, as described above, loss can also be reduced.
  • the reactor thus structured can provide comparatively high inductance with low levels of loss and noise.
  • the other end part of the second core section is coupled to the first core section, and the first core section further includes a projection extending from a peripheral edge portion that forms the aperture part into the first core.
  • the other end part of the second core section is positioned in a second aperture part provided in the first core section, with a second gap left between a circumference face of the other end part and a circumference face of the second aperture part.
  • the reactor thus structured includes a plurality of gaps, that is, the gap (first gap) and the second gap, the gaps can be arranged separately. For this reason, the reactor thus structured can reduce magnetic flux leaking outside, and as a result, can minimize the influence of leakage flux on peripheral devices arranged around the reactor.
  • the above-described reactor further includes a mount member on which the reactor is to be mounted.
  • the mount member is formed of a material having electrical conductivity and thermal conductivity, and has, on a mount surface on which the reactor is to be mounted, a slit hole whose longitudinal direction intersects the second gap in plan view, as viewed in the axial direction of the coil and that penetrates through the mount member, or a slit groove whose longitudinal direction intersects the second gap in plan view and that has a depth larger than or equal to a distance of the second gap.
  • the mount member since the mount member has thermal conductivity, it can radiate heat produced in the reactor.
  • the reactor has the second gap, since the mount member has electrical conductivity, leakage flux leaking out due to the second gap may cause eddy current in the mount member.
  • the flow of the eddy current is prevented because the mount member has the slit hole or the slit groove. Therefore, such a reactor can radiate heat without causing any power loss and any inductance change.
  • the other end part of the second core section is provided with a third gap from the other interior surface of the first core section.
  • the reactor thus structured includes a plurality of gaps, that is, the gap (first gap) and the third gap, the gaps can be arranged separately. For this reason, the reactor thus structured can reduce magnetic flux leaking outside, and as a result, can minimize the influence of leakage flux on peripheral devices arranged around the reactor.
  • a ratio t/W of a thickness t in a radial direction to a width W of the conductor member of the coil is 1/10 or less.
  • the reactor thus structured can further reduce eddy current loss.
  • the thickness t of the conductor member of the coil is smaller than or equal to a skin depth with respect to a frequency of alternating-current power to be fed to the reactors.
  • the reactor thus structured can further reduce eddy current loss.
  • the first core section has magnetic isotropy, and is formed of soft magnetic powder.
  • the first core section can comparatively easily obtain a desired magnetic characteristic, and can be comparatively easily molded in a desired shape.
  • the first core section is formed by a ferrite core having magnetic isotropy.
  • the first core section can comparatively easily obtain a desired magnetic characteristic, and can be comparatively easily molded in a desired shape.
  • the above-described reactors each further includes a heat transfer material to be filled in a gap provided between the coil and the first core section.
  • the coil is formed by a plurality of sub-coils and is divertible to a transformer.
  • the coil is formed by a plurality of sub-coils, and the sub-coils are stacked in the axial direction of the coil.
  • the coil is formed by a plurality of sub-coils, and the sub-coils are stacked in a radial direction of the coil.
  • the coil is formed by coiling a plurality of band-shaped conductor members such that a width direction of the conductor members follows the axial direction of the coil and such that the conductor members form layers stacked in a radial direction with insulating layers being disposed therebetween.
  • a reactor can be provided.

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JP5288228B2 (ja) 2007-01-30 2013-09-11 日立金属株式会社 リアクトル磁心およびリアクトル

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* Cited by examiner, † Cited by third party
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JP2014110394A (ja) * 2012-12-04 2014-06-12 Mitsumi Electric Co Ltd インダクタ
US11114232B2 (en) 2017-09-12 2021-09-07 Raycap IP Development Ltd Inductor assemblies
US11798731B2 (en) 2017-09-12 2023-10-24 Raycap, S.A. Inductor assemblies and methods for forming the same
WO2021180744A1 (fr) * 2020-03-11 2021-09-16 Raycap, S.A. Ensembles inducteurs et ses procédés de formation

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CN102971813B (zh) 2016-05-04
WO2012011276A1 (fr) 2012-01-26
KR20130020841A (ko) 2013-02-28
EP2597656A4 (fr) 2015-06-17
CN102971813A (zh) 2013-03-13
JP5662255B2 (ja) 2015-01-28
KR101427542B1 (ko) 2014-08-07
JP2012044150A (ja) 2012-03-01

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