JP2007287956A - Reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor in which cost reduction is implemented while contributing the weight reduction of outdoor unit of an air conditioner. <P>SOLUTION: In the reactor, a coil 3 composed of a conductor 5 made of aluminum foil or wire having oxide film 6 in its surface is wound around a center magnetic leg 1a of a laminated E-type iron core, and the contour of the coil 3 and the window contour of the laminated E-type iron core 1 are made to have an area contact structure through an insulating paper, thereby the temperature of the coil 3 is lowered, the equivalent amount to the margin of the temperature limit of the nearby insulating material is used for reducing the conductor cross section, the dimensional margin inside of the iron core window produced by the reduction of the conductor cross section allows the use of a compact size iron core whose magnetic path length is short, making the coil weight and the iron weight reduced. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a reactor used for power factor improvement such as an inverter air conditioner.

  Conventionally, as this type of reactor, a coil made of copper or aluminum round wire having an enamel film baked on its surface is wound (see Patent Document 1).

FIG. 3 shows a perspective view of the conventional reactor described in the above document. In FIG. 3, a coil 3 made of copper or aluminum round wire is wound around the surface of a central magnetic leg 1a of a laminated E-type iron core 1 and an enamel film provided with insulating paper 4 constituting insulating means is baked on the surface. The laminated E-type iron core 1 and the laminated I-type iron core 2 were butted so as to form an air gap 7, fixed by welding, and impregnated with varnish.
Japanese Utility Model Publication No. 6-31122 (FIG. 13)

  However, in the conventional configuration, the coil turns are point-contacted between the turns, and when a current flows in, the temperature difference inside the coil is increased due to heat generation of the conductor, and between the laminated E-type iron core having the function of the coil heat sink and the coil Is also a point contact through insulating paper, the heat conduction area between the laminated E-type iron core and the coil is small, and the heat dissipation effect of the coil is reduced. In order to suppress the following, it is necessary to design the coil with a large conductor cross-sectional area to reduce the resistance loss of the coil, and it is necessary to increase the coil weight and to design a large area in the window of the iron core into which the coil is inserted. For this reason, the iron core magnetic path length is increased, the iron core weight is increased, and it is not possible to contribute to the weight reduction of the air conditioner outdoor unit.

  The present invention solves the above-described conventional problems, and provides a lightweight and inexpensive reactor that contributes to weight reduction of an air conditioner outdoor unit by improving heat conduction between coil turns and between coil iron cores. Objective.

  In order to solve the above-mentioned conventional problems, the reactor of the present invention has a coil formed by conducting an aluminum foil / strip having an oxide film on its surface, and the outer shape of the coil is interposed between a laminated E-type iron core and insulating paper. It has a surface contact structure and is impregnated with varnish.

  The reactor of the present invention improves the heat conduction inside the coil and between the coil cores, and can be made light and inexpensive.

  The present invention has a structure in which a coil made of an aluminum foil / strip having an oxide film on its surface is wound, and by increasing the contact area between the coil turns and between the coil cores, This makes it possible to improve the heat conduction of the laminated E-type iron core having the function of the coil heat sink, improve the heat uniformity and heat dissipation inside the coil, and contribute to the weight reduction and cost reduction of the air conditioner.

Embodiments of the present invention will be described below with reference to the drawings. Note that the present invention is not limited to the present embodiment.

(Embodiment 1)
FIG. 1 is a front sectional view of a reactor according to Embodiment 1 of the present invention, and FIG. 2 is an explanatory view of a manufacturing method. 1 and 2, the same components as those in FIG.

  In FIG. 1 and FIG. 2, the coil 3 using the aluminum foil formed on the surface thereof with an oxide film 6 of Al2O3, which is an insulator, by a known electrochemical method for producing an electrode foil of an aluminum electrolytic capacitor is used as the coil 3. Insulating paper 4 made of aromatic polyamide or the like for electrical insulation between 3 and the iron core is wound and attached to the central magnetic leg 1a of the laminated E-type iron core 1 made of silicon steel plate, and then the laminated I-type iron core 2 is connected to the air gap 7 Are formed, butted and fixed by welding, impregnated with a varnish made of unsaturated polyester, and fixed. The value of the outer dimension W1 of the coil 3 around which the insulating paper 4 attached to the laminated E-type iron core 1 is wound is made several mm larger than the window outer dimension W2 of the laminated E-type iron core 1.

  In this embodiment, since the aluminum foil having an appropriate electrical insulation is used with the very thin oxide film 6 of Al2O3 between the turns of the coil 3, the thermal insulation of the oxide film 6 is sufficient. In addition, since the foil is used, a surface contact structure is obtained, and the heat conduction inside the coil 3 is improved, so that when the current flows in, the internal temperature of the coil 3 due to the heat generated by the conductor becomes uniform, and the coil 3 The maximum temperature decreases.

  Moreover, even if the value of the outer dimension W1 of the coil 3 wound with the insulating paper 4 is larger than the window outer dimension W2 of the laminated E-type iron core 1 due to the flexibility of the aluminum foil, it can be easily attached to the laminated E-type iron core 1. The laminated E-type iron core 1 having the functions of the outer shape of the coil 3 and the coil heat radiation plate has a surface contact structure through the insulating paper 4 due to the deformation of the coil 3 and the reaction after the mounting. The heat dissipation is improved, and the maximum temperature of the coil 3 is lowered.

  As a result, when the current flows in, the maximum temperature of the electrical insulating material adjacent to the coil 3 due to the heat generation of the conductor 5 of the coil 3 can afford a temperature limit of the insulation class stipulated by law. Even if the cross-sectional area of the conductor is reduced and the resistance loss is increased, the temperature limit stipulated by law can be cleared and the weight of the conductor can be reduced.

  Furthermore, by reducing the cross-sectional area of the coil 3, it is possible to reduce the size of the core with a small magnetic path length and a lightweight core, and the core weight can also be reduced. As a result, a light and inexpensive reactor can be obtained.

  Since the reactor of the present invention can improve the heat dissipation of the coil, it can be applied to the use of an inductor / transformer using a laminated core.

Sectional drawing of the reactor in Embodiment 1 of this invention Explanatory drawing of the manufacturing method of the reactor in Embodiment 1 of this invention Perspective view of conventional reactor

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Laminated E type iron core 1a Central magnetic leg 2 Laminated I type iron core 3 Coil 4 Insulating paper 5 Conductor 6 Oxide film 7 Air gap W1 Coil outer dimension W2 Laminated E type iron core window outer dimension

Claims (1)

An air gap that has a laminated E-type iron core and a laminated I-type iron core that face each other, and that adjusts magnetic saturation characteristics between a central magnetic leg of the laminated E-type iron core and the laminated I-type iron core disposed opposite thereto A coil made of an aluminum foil / strip having an oxide film on its surface is wound around the center magnetic leg through insulating paper, and the outer shape of the coil is insulated from the laminated E-type iron core with the insulation. A reactor having a surface contact structure through paper and impregnated with varnish.

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