JP2002093644A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor which suppresses contraction occurred at welding, prevents the non-uniformity of a gap dimension by welding conditions, can appropriately keep the gap dimension, improves mechanical strength against shocks and can prevent the deviation of the gap dimension due to shocks, such as a drop. SOLUTION: Since a metal fitting 3 for fixing the upper parts of cores 2 and 2' is installed on the upper faces of a pair of U-shaped cores 2 and 2', contraction in an inner direction, which is below the fitting board 4 and the cores 2 and 2', is suppressed with the fitting tool 3 by the welding at the time of welding the fitting board 4 to the lower faces of the cores 2 and 2'. Thus, a magnetic gap between upper outer legs 2a and 2a' inserted into the hollow part of the coils 2 and 2' can be kept constant.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reactor incorporated in consumer electronic equipment, for example, an inverter air conditioner.

[0002]

2. Description of the Related Art Inverter air conditioners have improved power factor,
Insert the reactor into the power supply circuit for the purpose of harmonic suppression, etc.
Inverter control is being performed.

As this type of reactor, there is a reactor in which a UU type is used as a pair of cores, the cores are incorporated in a coil, and a mounting plate is attached to the assembly.

[0004] In this UU-shaped core, a magnetic gap is formed between each opposing outer leg of one of a pair of cores. In this case, if a magnetic gap is formed on one of the outer legs, it must be supported by the other outer leg, and it is difficult to maintain a predetermined gap of the air gap. Is unfavorable because of variation.

[0005] A mounting plate is mounted on the coil incorporating the pair of UU-shaped cores, and the integration of each core and the mounting of the mounting plate to each core are performed by welding. If this is done, the gap of the magnetic gap may be increased.

FIG. 7 shows a pair of UU-shaped cores 2 on a coil 1.
2 shows a conventional example in which a mounting plate 4 is welded to each of the UU-shaped cores 2 and 2 '. In the figure, reference numerals 5 and 7 are welding portions.

[0007]

FIG. 8 shows the welding procedure. Conventionally, first, as shown in FIG. 8, a pair of UU-shaped cores 2 and 2 'are assembled into a coil 1 and outer legs 2b and 2b of the butted cores 2 and 2' located outside the coil 1. Weld the center of the bottom of the '
And

[0008] Next, as shown in FIG.
Welding is performed on both ends of 2 ′ and both ends of the mounting bracket 4 to form a welded portion 7.

[0009] However, in the welding in such a procedure, as shown in FIG.
The cores 2 and 2 ', which had been matched with the fulcrum, open,
There was a problem that an appropriate gap size could not be obtained. As described above, it is considered that the contraction in the direction B influences the opening of the cores 2 and 2 ′.

In addition, when mass-produced due to a difference in welding conditions, the gap dimension is not constant, and the electric characteristics are varied, which is not preferable as a product.

Further, in welding at a total of three places, ie, a central welded portion 5 below the cores 2 and 2 'and welded portions 7 at both ends, there is a possibility that a gap size may be changed due to an impact such as a drop.

The present invention has been proposed in view of the above, and has as its object to suppress shrinkage occurring at the time of welding, prevent unevenness in gap size due to welding conditions, and adjust the gap size appropriately. Another object of the present invention is to provide a reactor capable of improving the mechanical strength against impact and the like, and preventing the gap size from being disordered by the impact such as dropping.

[0013]

According to the present invention, each outer leg 2 above a pair of U-shaped cores 2 and 2 'is provided in a hollow portion 1a of a coil 1.
a, 2a 'are inserted to form a magnetic gap between the opposing surfaces of the outer legs 2a, 2a', and a metal fitting 3 is inserted into a gap between the upper surface of each of the outer legs 2a, 2a 'and the coil 1.
And insert each outer leg 2b, 2b below each U-shaped core 2, 2 '.
b ′ is arranged on the lower surface side of the coil 1 and butted, the center of the bottom surface is defined as a welded portion 5, both ends of the metal fitting 3 and each U-shaped core 2,
2 'is welded to the upper portion of the outer surface to form a welded portion 6, and each U
The above-mentioned object is achieved by providing a mounting member 4 on the lower surface side of the shaped cores 2 and 2 ', and welding the mounting metal member 4 to both ends of the lower surface of each of the U-shaped cores 2 and 2' to form a welded portion 7. ing.

An outer leg 2a above one U-shaped core 2
A metal fitting 3 having bent portions 3a at both ends is placed on the upper surface of the coil 1 and inserted into the hollow portion 1a of the coil 1, and the outer leg 2a 'of the other U-shaped core 2' is inserted into the hollow portion 1a of the coil 1. A magnetic gap is formed between the opposing surfaces of the outer legs 2a and 2a ', and the bent portions 3a of the metal fitting 3 abut and press against the upper portions of the outer surfaces of the cores 2 and 2'. The outer legs 2b and 2b 'below the cores 2 and 2' are arranged and butted on the lower surface of the coil 1, and the center of the bottom surface is a welded portion 5, and the lower surface of the U-shaped cores 2 and 2 ' A mounting bracket 4 is provided.
And the lower end portions of the U-shaped cores 2 and 2 ′ are welded to each other to form a welded portion 7, thereby achieving the above object.

[0015]

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to each U-shaped core 2, 2 '.
A metal fitting 3 functioning as a fixing plate for preventing the upper surface side of each of the U-shaped cores 2 and 2 'from expanding is provided on the upper surface of. Therefore, the mounting plate 4 is provided on the lower surface side of each U-shaped core 2, 2 ', and each U-shaped core 2, 2' is contracted in the inward direction when the lower ends of both ends of each U-shaped core 2, 2 'are welded. One of the outer legs 2 on the upper side of each U-shaped core 2, 2 '
The magnetic gap between a and 2a 'is kept constant.

[0016]

FIG. 1 is an exploded perspective view of one embodiment of the present invention, FIG. 2 is a perspective view showing an assembled state, and FIG. 3 is a side view for explaining a welded state.

First, in FIG. 1, 1 is a bobbinless coil, and 2 and 2 'are a pair of U-shaped cores.

Each U-shaped core 2, 2 'is inserted into the hollow portion 1a of the coil 1, and each of the upper outer legs 2a, 2a' in which a magnetic gap is formed between opposing end surfaces, and the U-shaped core 2, 2 '. It has a lower outer foot 2b, 2b 'which is located on the lower outer surface side, and whose opposing end faces are abutted and joined to each other, and is formed substantially in a substantially U-shape as a whole.

Reference numeral 3 denotes a thin flat metal fitting provided on the upper surface of each of the upper outer feet 2b and 2b 'and made of a non-magnetic material such as stainless steel. The metal fitting 3 has a substantially rectangular shape and corresponds to the shape of the upper surface of each of the outer feet 2a and 2a '.

Reference numeral 4 denotes a mounting bracket made of a steel plate which is mounted on the lower surface of each of the lower outer feet 2b and 2b 'by welding.

The mounting bracket 4 has a flat plate shape, and is formed in a generally rectangular simple shape as a whole. Holes 4a for mounting to a mounting surface (not shown) using screws (not shown) are formed in corner portions at both ends in the length direction.

In assembling, as shown in FIG.
A pair of U-shaped cores 2 and 2 ′ are arranged on both sides of the coil 1, and the upper outer legs 2a and 2a ′ are inserted into the hollow portion 1a of the coil 1 as shown in FIGS. . The end faces of the lower outer feet 2b, 2b 'are butted and joined.

A gap is formed between the upper part in the hollow part 1a of the coil 1 and the upper surface of each of the outer feet 2a, 2a '.
The flat metal fitting 3 is inserted into that portion.

Each outer leg 2 below each core 2, 2 '
The mounting plate 4 is located on the lower surfaces of b and 2b '.

An insulating paper (not shown) is inserted between the coil 1 and each of the U-shaped cores 2 and 2 '.

The welding is performed according to the following procedure.

First, each outer leg 2 below each core 2, 2 '
The bottom surfaces of the butted portions b and 2b 'are welded. 5 is the welded portion.

Next, the coil 1 and the upper outer legs 2a, 2
a 'and the outer legs 2a, 2a'
And weld the joint. 6 is the welded portion.

Next, the lower outer legs 2b, 2b 'are welded to both ends of the mounting plate 4 in the width direction to form a welded portion 7.

In this case, since each core 2, 2 'and the metal fitting 3 are welded at both ends thereof, the mounting metal 4
And the cores 2 and 2 ′ can be prevented from contracting during welding.

Therefore, the size of the magnetic gap between the upper outer feet 2a and 2a 'can be maintained constant without changing.

Further, the upper and lower surfaces of the cores 2 and 2 'are welded, and the welded portions 5 to 7 are provided in a total of five places, so that the strength is improved. Therefore, the size of the magnetic gap can be kept constant even with impact or the like.

[0033]

Embodiment 2 FIGS. 4 to 6 show a second embodiment of the present invention.
In this embodiment, the size of the magnetic gap is made constant while reducing the number of welding steps and improving the productivity.

That is, both ends of the metal fitting 3 made of a non-magnetic material such as stainless steel are bent downward in a substantially L-shape to form bent parts 3a, respectively.
The inner wall surfaces of the cores 2 and 2 ′ are configured to abut and press the outer surface upper portions 2c and 2c ′ of the cores 2 and 2 ′, respectively.

In assembling, first, a metal fitting 3 having bent portions 3 a at both ends is placed on the upper surface of the outer leg 2 a above one core 2, and inserted into the hollow portion 1 a of the coil 1.

Next, the outer leg 2 above the other core 2 '
a ′ is inserted into the hollow portion 1 a of the coil 1.

In this state, the upper outer feet 2a, 2a
The metal fitting 3 is arranged on the upper surface of a ′, and a magnetic gap is formed between the opposing end surfaces, and the opposing end surfaces of the lower outer legs 2b, 2b ′ are joined.

Next, the other outer foot 2 of each of the cores 2 and 2 '
b, 2b 'are welded to the bottom surface
And

Next, the lower outer legs 2b, 2b 'are welded to both ends of the mounting plate 4, respectively, to form welds 7. In this case, both ends of the upper surfaces of the cores 2, 2' are metal fittings. 3 are held down by the bent portions 3a, so that the shrinkage in the B direction and the tensile force in the C direction, which occur when the mounting bracket 4 and the cores 2, 2 'are welded, can be suppressed, and the magnetic gap can be reduced. The dimensions can be kept constant.

The assembling procedure is not necessarily limited to the above example. First, the metal fitting 3 is placed on the other core 2 ', inserted into the hollow portion 1a of the coil 1, and then the one core 2' It is needless to say that it is possible to assemble the apparatus by inserting the outer feet.

The other configuration is the same as that of the above-described embodiment.

[0042]

As described above, according to the present invention, since the metal fittings 3 for fixing the upper parts of the cores 2 and 2 'are provided above the pair of UU-shaped cores 2 and 2', When the mounting plate 4 is welded to the lower part of the coil 2, 2 ', the shrinkage in the inward direction below the mounting plate 4 and the cores 2, 2' can be suppressed by the metal fitting 3, so that the hollow portion 1a of the coil 2, 2 ' The magnetic gap between each of the outer legs 2a, 2a 'inserted into the inside can be kept constant.

Since the mechanical strength is increased by the metal fitting 3, the impact resistance and the like can be improved.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of a first embodiment of the present invention.

FIG. 2 is an assembled perspective view of the same.

FIG. 3 is a side view showing a welding state of the same.

FIG. 4 is an exploded perspective view of a second embodiment of the present invention.

FIG. 5 is an assembled perspective view of the same.

FIG. 6 is a side view showing a welding state of the above.

FIG. 7 is a perspective view of a conventional example.

FIG. 8 is an explanatory view of a conventional welding process, and FIG. 8 is an explanatory view of a defect of the conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Coil 1a ... Hollow part 2, 2 '... U-shaped core 2a, 2a' ... One outer leg 2b, 2b '... The other outer leg 2c, 2c' ... Upper outer surface 3 ... Metal fitting 3a ... Bending part 4 ... Mounting plate 4a ... Mounting holes 5-7 ... Welded part

Claims (2)

[Claims] An outer leg (2a) above a pair of U-shaped cores (2) and (2 ') is provided in a hollow portion (1a) of a coil (1).
(2a ′), and insert these outer feet (2a), (2a ′).
a ′) while forming a magnetic gap between the opposing surfaces,
A metal fitting (3) is inserted into a gap between the upper surface of each of these outer legs (2a) and (2a ') and the coil (1), and each lower part of each U-shaped core (2) and (2'). Outer feet (2b), (2b ')
Are arranged on the lower surface side of the coil (1), butted against each other, and the center of the bottom surface is used as a welded portion (5). Are welded to form a welded portion (6), and a mounting bracket (4) is provided on the lower surface side of each of the U-shaped cores (2) and (2 '), and the mounting bracket (4) and each U-shaped core (2) are provided. , (2 ′), a welded portion (7) by welding both ends of the lower surface. 2. An outer foot (2) above one U-shaped core (2).
Metal fitting (3) having bent portions (3a) at both ends on the upper surface of a)
Is placed in the hollow portion (1a) of the coil (1), and the outer leg (2a ') of the other U-shaped core (2') is inserted into the coil (1).
Into each of the outer legs (2a),
A magnetic gap is formed between the opposing surfaces of (2a '), and each bent portion (3a) of the metal fitting (3) is formed by each core (2),
Each outer foot (2b), (2b ') under the U-shaped cores (2), (2') by abutting and pressing against the upper outer surface of (2 ').
Are arranged on the lower surface side of the coil (1) and butted, the center of the bottom surface is used as a welded portion (5), and each U-shaped core (2)
A mounting bracket (4) is provided on the lower surface side of (2 ′), and the mounting bracket (4) is welded to both ends of the lower surface of each of the U-shaped cores (2) and (2 ′) to form a welded portion (7). A reactor characterized by: