JP2009267074A - Reactor apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor apparatus which meets the need of a large current and a high frequency when a high frequency current with a direct current superimposed thereon is allowed to flow, and which is made compact while suppressing heat generation and loss. <P>SOLUTION: The reactor apparatus includes a coil obtained by winding a flat wire in a width direction. The flat wire has a three-layer structure obtained by laminating three flat wires which are electrically insulated from each other. Preferably, respective thicknesses of the three flat wires are determined so that the thickness of the flat wire at the midmost of the three-layer structure is thicker than that of the flat wires on both ends of the three-layer structure. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a reactor device, and more particularly to a reactor device using a rectangular wire.

  Various techniques have been disclosed so far for a reactor device formed by winding a coil around a core. For example, it is patent documents 1-3.

JP 2004-327569 A JP 2002-43136 A JP 2004-87607 A

  When a high-frequency current superimposed with a direct current as shown in FIG. 8 is passed through such a reactor device, the direct current component Io can be adapted to a large current and the alternating current component io can be adapted to a high frequency. is required.

  In order to cope with an increase in current, generally the cross-sectional area of the conducting wire constituting the coil is increased. Thereby, even if the current increases, heat generation can be suppressed. On the other hand, in order to cope with higher frequencies, the surface area of the conducting wire constituting the coil is generally increased. This is because at a high frequency, the skin effect becomes conspicuous, and current flows concentrated on the surface. Therefore, in order to reduce the loss at high frequency, it is necessary to increase the surface area.

  Conventionally, reactor devices are also required to be downsized due to restrictions on mounting space.

  In Patent Document 1, a flat wire is used for the coil. In this structure, it is necessary to reduce the thickness of the rectangular wire in order to reduce the size of the reactor device in response to higher frequencies. In addition, it is necessary to increase the width of the rectangular wire in order to secure a cross-sectional area necessary for flowing a large current. However, if the width of the rectangular wire is increased, the current becomes non-uniform in the width direction due to the skin effect, current becomes difficult to flow in the center, and the effective cross-sectional area through which the current flows decreases. Will increase.

  In Patent Document 2, a round wire having a circular cross-sectional shape is used for the coil. In this structure, it is necessary to make the round line thinner in order to prevent the current from flowing through the central portion due to the skin effect and suppressing the effective area from decreasing. However, if the round wire is made thin, the cross-sectional area necessary for flowing a large current cannot be secured. There is also a method of bundling thin round wires so that a large current can flow, but processing the coil into a coil, but the current concentrates on the round wires on the outer peripheral side, so the loss cannot be reduced. Furthermore, in order to solve this, there is a method of using a litz wire in which thin round wires are bundled and twisted together, but there is a problem that the cost is high.

  In Patent Document 3, a flat folding curve formed by bending a flat wire in the width direction is used for the coil. In this structure, the width of the flat folding curve must be increased in order to allow a large current to flow while suppressing an increase in loss due to the skin effect. Therefore, in a reactor device that is required to be miniaturized, when a flat folding curve is wound around a small core, the insulation film is pulled and stretched on the outer peripheral side of the flat folding curve, thereby reducing the thickness. As a result, the withstand voltage performance may be degraded, or the insulating coating may be damaged. Therefore, there exists a problem in size reduction of a core, and the external shape of the reactor apparatus containing a core will become large.

  The present invention has been proposed in view of the above problems. An object of the present invention is to provide a reactor device that can cope with an increase in current and frequency when flowing a high-frequency current superimposed with a direct current, suppresses heat generation and loss, and can be miniaturized.

  The reactor apparatus which concerns on 1st invention is provided with the coil formed by winding a flat wire in the width direction. The flat wire has a three-layer structure in which three flat wires that are electrically insulated from each other are stacked.

  According to the first aspect of the present invention, a coil is formed by winding a rectangular wire having a three-layer structure in which three rectangular wires are overlapped, so-called edgewise in the width direction. Here, a flat wire means a conducting wire having a rectangular cross-sectional shape. As a result, the DC component mainly flows through the middle rectangular wire of the three-layer structure, and the AC component mainly flows through the rectangular wires at both ends of the three-layer structure. Therefore, a large current can be passed while suppressing an increase in loss due to the skin effect.

  In addition to the configuration of the first invention, the reactor device according to the second invention is such that the thickness of each of the three flat wires is equal to the thickness of the flat wire in the middle of the three-layer structure is the flat angle at both ends of the three-layer structure. The thickness is greater than the thickness of the line.

  As a result, a large DC current mainly flows through a thick rectangular wire in the middle, and a high-frequency current mainly flows through thin rectangular wires wound at both ends so as to sandwich the thick rectangular wire in the middle. it can. Therefore, a large current can be passed while suppressing an increase in loss due to the skin effect, and the coil can be downsized.

  The reactor apparatus which concerns on 3rd invention is provided with the coil formed by winding a flat wire in the width direction. The rectangular wire has a multilayer structure symmetrical in the thickness direction in which four or more rectangular wires electrically insulated from each other are stacked.

  According to the third aspect, a coil is formed by winding a flat wire having a multilayer structure symmetrical in the thickness direction, in which four or more flat wires are overlapped, in the width direction so-called edgewise. Thereby, the direct current component mainly flows through a rectangular wire on the inner layer side of the multilayer structure, and the alternating current component mainly flows through a rectangular wire on the outer layer side of the multilayer structure. Therefore, a large current can be passed while suppressing an increase in loss due to the skin effect.

  In the reactor device according to the fourth invention, in addition to the structure of the third invention, the thickness of each of the four or more rectangular wires is equal to the thickness of the rectangular wire on the inner layer side of the multilayer structure on the outer layer side of the multilayer structure. The thickness is equal to or greater than the thickness of the flat wire.

  As a result, a large DC current mainly flows through a thick rectangular wire on the inner layer side, and a high-frequency current mainly flows through a thin rectangular wire on the outer layer wound so as to sandwich the thick rectangular wire on the inner layer side. can do. For this reason, it is possible to secure a region for each frequency component of the current, flow a large current while suppressing an increase in loss due to the skin effect, and to reduce the size of the coil.

  According to the reactor device of the present invention, when a high-frequency current superimposed with a direct current is passed, it is possible to cope with a large current and a high frequency, thereby suppressing heat generation and loss and miniaturization.

  With reference to FIGS. 1-3, the structure of the reactor apparatus of this invention is demonstrated. FIG. 1 is a perspective view showing an example of the appearance of the reactor device of the present invention. FIG. 2 is a front view of the reactor device shown in FIG. FIG. 3 is a cross-sectional view of the reactor device shown in FIG. FIG. 3 is a cross-sectional view in which the reactor device is cut along the cutting line XX indicated by the alternate long and short dash line in the front view of FIG. 2 and the cut surface is viewed in the direction indicated by the arrow.

  This reactor device 100 includes U-shaped cores 110 and 120, four I-shaped cores 160, and coils 130 and 140. The coils 130 and 140 are wound around the U-shaped cores 110 and 120 and the I-shaped core 160. The coils 130 and 140 are formed by winding a rectangular wire in the width direction in a so-called edgewise manner. Further, as shown in FIG. 3, an air gap is formed between the U-shaped core 110 and the I-shaped core 160, between the I-shaped cores 160 and 160, and between the I-shaped core 160 and the U-shaped core 120. 150 is formed.

  The coils 130 and 140 will be described in detail with reference to FIG. FIG. 4 shows coils 130 and 140 according to the first embodiment of the reactor device of the present invention. For the sake of explanation, a part of the coils 130 and 140 is shown enlarged in FIG. As shown in FIG. 4, in the first embodiment, coils 130 and 140 are formed by winding a rectangular wire having a three-layer structure in which three rectangular wires are overlapped, edgewise.

  The coils 130 and 140 according to the first embodiment will be described in more detail with reference to FIG. FIG. 5 is a side view of a rectangular wire constituting the coils 130 and 140 according to the first embodiment. The rectangular wires constituting the coils 130 and 140 have a three-layer structure in which the rectangular wire A is sandwiched between the rectangular wires B from both sides. An insulating coating is applied to the surface of each of the flat wires A and B, and the flat wire A and the flat wire B are electrically insulated from each other. The thickness a of the flat wire A and the thickness b of the flat wire B satisfy a ≧ b.

  An operation of the reactor device including the coils 130 and 140 configured as described above will be described. The rectangular wires constituting the coils 130 and 140 have a three-layer structure in which rectangular wires A and B having different thicknesses, which are electrically insulated from each other, are stacked. For this reason, when a high frequency current in which a direct current is superimposed flows in the reactor device, the direct current mainly flows through a thick rectangular wire A in the middle, and the high frequency current mainly flows through a thin rectangular wire B at both ends. Therefore, it is possible to divide the regions through which direct current and high frequency current flow. As a result, the loss due to the skin effect of the high-frequency current can be suppressed. Further, since the direct current mainly flows through the thick rectangular wire A, heat generation can be suppressed even if the current increases.

  Furthermore, if the thickness b of the flat wire B is less than or equal to the skin (penetration) depth, the high-frequency current flows almost uniformly in the cross section of the flat wire B. Therefore, the influence of the skin effect of the high frequency current is reduced. Therefore, the thickness a of the flat wire A is relatively reduced, so that the cross-sectional area necessary for flowing a large current can be secured. As a result, in the coils 130 and 140 according to the first embodiment, it is not necessary to increase the width of the rectangular wire, the coil can be reduced in size, and the outer shape of the reactor device can be reduced.

  With reference to FIG. 6, the coils 130 and 140 which concern on 2nd Embodiment of the reactor apparatus of this invention are demonstrated. FIG. 6 is a side view of a rectangular wire constituting the coils 130 and 140 according to the second embodiment. The rectangular wires constituting the coils 130 and 140 have a five-layer structure symmetrical in the thickness direction in which the rectangular wire A is sandwiched between the rectangular wires B and C from both sides. An insulating coating is applied to the surface of each of the flat wires A, B, and C, and the flat wire A, the flat wire B, and the flat wire C are electrically insulated from each other. The thickness a of the flat wire A, the thickness b of the flat wire B, and the thickness c of the flat wire C are a ≧ b ≧ c.

  An operation of the reactor device including the coils 130 and 140 configured as described above will be described. The rectangular wires constituting the coils 130 and 140 have a five-layer structure symmetrical in the thickness direction in which the rectangular wires A, B and C having different thicknesses, which are electrically insulated from each other, are stacked. For this reason, when a high-frequency current in which a direct current is superimposed flows in this reactor device, the direct-current flows mainly around the thick rectangular wire A on the inner layer side, and the high-frequency current mainly flows around the thin rectangular wire C on the outer layer side. . Therefore, since the regions through which the direct current and the high-frequency current flow can be divided, the loss due to the skin effect of the high-frequency current can be suppressed also in the second embodiment, as in the first embodiment. Further, since the direct current flows mainly around the thick rectangular wire A, heat generation can be suppressed even if the current increases.

  Generally, a high frequency current includes a plurality of frequency components. In the second embodiment, as described above, the rectangular wires constituting the coils 130 and 140 have a five-layer structure. Therefore, it is possible to secure a region that flows for each frequency component of the current. By limiting the region for each frequency component of the current, an increase in loss due to the skin effect can be suppressed. For this reason, also in the second embodiment, the thickness a of the flat wire A is relatively reduced from the need to reduce the thickness, so that a cross-sectional area necessary for flowing a large current can be secured. As a result, it is not necessary to increase the width of the rectangular wire even in the coils 130 and 140 according to the second embodiment, the coil can be reduced in size, and the outer shape of the reactor device can be reduced.

  As described above in detail, according to the first embodiment of the present invention, the coil 130 is formed by a rectangular wire having a three-layer structure in which the rectangular wire A and the rectangular wire B that are electrically insulated from each other are overlapped. 140 are formed. The thickness a of the flat wire A and the thickness b of the flat wire B satisfy a ≧ b. As a result, it is possible to divide the regions where the direct current and the high-frequency current flow.

  In addition, according to the second embodiment of the present invention, the coils 130 and 140 are formed by a rectangular wire having a five-layer structure in which the rectangular wire A, the rectangular wire B, and the rectangular wire C that are electrically insulated from each other are overlapped. It is formed. The thickness a of the flat wire A, the thickness b of the flat wire B, and the thickness c of the flat wire C are a ≧ b ≧ c. Thereby, the area | region which flows for every frequency component of an electric current can be ensured.

  Both the first and second embodiments of the reactor device of the present invention can cope with an increase in current and frequency when flowing a high-frequency current superimposed with a direct current, suppresses heat generation and loss, and reduces the size of the reactor device. Is possible.

  In addition, since the reactor device of the present invention uses a rectangular wire, a bobbin is unnecessary when winding, and there is an advantage that machining into a coil is easier compared to a round wire. Furthermore, there is an advantage that the cost is lower than that of the litz wire.

  Generally, in a reactor device, it is known that the core can be reduced in size when the frequency is increased. As described above, in the reactor device of the present invention, it is possible to cope with high frequency, and since there is no need to increase the width of the rectangular wire, there is no risk of damage to the insulating coating even if it is wound around a small core. . Therefore, in the reactor device that is required to be downsized, the core can be downsized, and the outer shape of the reactor device including the core can be reduced.

  Note that the present invention is not limited to the above-described embodiment, and it goes without saying that various improvements and modifications can be made without departing from the spirit of the present invention.

  The layer structure of the rectangular wire forming the coil may be symmetric in the thickness direction. By winding four or more rectangular wires on top of each other, a larger current can be handled. For example, a four-layer structure as shown in FIG. In FIG. 7, if the thickness a of the flat wire A and the thickness b of the flat wire B satisfy a ≧ b, the same effect as in the above embodiment can be obtained. Also, including the first and second embodiments, the thickness of each of the flat wires A, B, and C may be such that the thickness of the flat wire on the inner layer side is equal to or greater than the thickness of the flat wire on the outer layer side, Needless to say, the same thickness may be used.

  Moreover, the shape of the core is arbitrary, and is not limited to the illustrated shape of the core. It is good also as an air core reactor without a core.

The perspective view which shows an example of the reactor apparatus of this invention. The front view. FIG. The enlarged view of the coil which concerns on this invention. The side view of the flat wire which comprises the coil which concerns on this invention (the 1). The side view of the flat wire which comprises the coil which concerns on this invention (the 2). The side view of the flat wire which comprises the coil which concerns on this invention (the 3). An example of a high-frequency current superimposed with a direct current.

Explanation of symbols

100 Reactor device 110, 120 U-shaped core 130, 140 Coil 150 Air gap 160 I-shaped core A, B, C Flat wire a, b, c Thickness of flat wire

Claims (4)

A reactor device including a coil formed by winding a flat wire in the width direction,
The flat wire is a reactor device having a three-layer structure in which three flat wires that are electrically insulated from each other are stacked.   2. The reactor device according to claim 1, wherein a thickness of each of the three rectangular wires is equal to or greater than a thickness of a rectangular wire at both ends of the three-layer structure. . A reactor device including a coil formed by winding a flat wire in the width direction,
The said rectangular wire is a reactor apparatus which has a multilayered structure symmetrical in the thickness direction which accumulated 4 or more rectangular wires electrically insulated mutually. 4. The reactor according to claim 3, wherein the thickness of each of the four or more rectangular wires is such that the thickness of the rectangular wire on the inner layer side of the multilayer structure is equal to or greater than the thickness of the rectangular wire on the outer layer side of the multilayer structure. apparatus.

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