JP2010118496A - Reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent vibration and noise generated at a gap by forcing a non-magnetic spacer into the gap provided in a core. <P>SOLUTION: When current flows in a reactor 10, electromagnetic vibration in a gap 6 is increased by the concentration of a magnetic flux. The electromagnetic vibration is a vibration such that a central leg 1a of an E-type core 1 and I-type core 2 are repeatedly drawn near and thrust away to each other, and noise is generated due to the vibration. Recessed parts 1e and 2a are respectively formed at an end face of a distal end part of the central leg 1a of an E-type core 1 and a lower surface center portion of the I-type core 2, a spacer 3 having projecting parts 3a and 3b with shapes corresponding to the recessed parts on an upper and lower part is inserted in the gap 6, and the E-type core 1, the central leg 1a and the I-type core 2 are firmly joined so that the vibration is suppressed and the generation of the noise is prevented. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a reactor used in various electric devices, and more particularly to a reactor in which a gap is provided in a magnetic path formed by a core for adjusting magnetic saturation characteristics.

  2. Description of the Related Art Conventionally, in reactors used in various electric devices, a gap is provided in a magnetic path formed of a core made of a magnetic material so as to prevent magnetic saturation in order to improve magnetic saturation characteristics due to a large current. In such a gap, magnetic flux is concentrated, and part of the core forming the gap is easily mechanically bent, so that the vibration noise is increased due to electromagnetic vibration of the core. there were.

  Therefore, it has been considered to inject an adhesive, which is a non-magnetic material, into the gap to increase the mechanical strength of the core in the gap and suppress vibration. However, in the configuration in which the adhesive is injected, there is a problem that the core often cracks when the adhesive is cured or subjected to a thermal shock due to a difference in thermal expansion coefficient between the core material and the adhesive. It was.

  In order to solve such a problem, Patent Document 1 proposes to mix non-magnetic particles having a thermal expansion coefficient close to that of the core material, for example, glass beads, into an adhesive and inject the adhesive into the gap. Yes. Thereby, it is possible to prevent the core from cracking due to the difference in thermal expansion coefficient, and to effectively suppress the vibration generated in the gap.

  However, in the above-described method, the nonmagnetic particles are mixed with the adhesive, which increases the material cost, and it is necessary to strictly control the mixing ratio of the adhesive and the nonmagnetic particles and the viscosity of the adhesive. Therefore, there is a problem that the management cost becomes high, resulting in an increase in cost. Further, when the adhesive is injected into the gap, it is very difficult to inject the adhesive only into the gap portion so that it does not leak to other places, and there is a problem that workability is poor.

  On the other hand, in Patent Document 2, it is proposed to suppress the vibration of the gap by inserting a spacer made of a nonmagnetic material into the gap in a reactor in which a magnetic path is formed by an E-type core and an I-type core. 4A and 4B are diagrams showing a reactor disclosed in Patent Document 2. FIG. 4A is a perspective view of the reactor, and FIG. 4B is an exploded view of the reactor.

  The reactor 100 includes a core composed of an E-type core 101 and an I-type core 102, and a coil 107. The E-shaped core 101 includes a middle leg 101a provided at the center, outer legs 101b and 101c provided on both sides thereof, and a connecting part 101d for connecting them. The end surfaces of the distal ends of the outer legs 101b and 101c are joined to the corresponding opposing surfaces of the I-type core 102.

  A coil 107 formed by winding an electric wire is incorporated in the middle leg 102a of the E-type core 101. An insulating paper 103 is wound around the outer periphery of the coil 107 located between the middle leg 102a and the outer leg 101b. Further, an insulating paper 104 is wound around the outer periphery of the coil 107 located between the middle leg 102a and the outer leg 101c. These insulating papers 103 and 104 are formed of an insulating material for insulating the coil 107.

  5A and 5B are perspective views showing the E-shaped core 101, where FIG. 5A is a diagram for explaining the installation of insulating paper, and FIG. 5B is a diagram for explaining the spacer installation. As shown in FIG. 5, the middle leg 101a is shorter than the outer legs 101b and 101c in order to form a gap 108 for adjusting the magnetic saturation characteristics.

  An insulating paper 105 is wound around the outer peripheral wall of the middle leg 101a. The insulating paper 105 is formed of an insulating material for insulating the middle foot 101a and the coil 107. The height of the insulating paper 105 is substantially the same as the length of the outer legs 101b and 101c (the distance from the end surfaces of the outer legs 101b and 101c to the connecting portion 101d). As a result, the gap 108 is partitioned by the insulating paper 105.

  In the gap 108, there is provided a spacer 106 having a rectangular parallelepiped shape substantially the same size as the gap 108 and having a hardness for suppressing vibration and made of a nonmagnetic material such as a synthetic resin. The size of the bottom surface of the spacer 106 is substantially the same as the end surface of the middle foot 101a, and the height is the same as the distance from the end surface of the middle foot 101a to the portion where the I-type core 102 is located. The spacer 106 is not fixed to the middle foot 101a, but is only placed in the gap 108.

  When manufacturing the reactor 100, first, the insulating paper 105 is wound around the middle leg 101 a of the E-shaped core 101. Thereafter, the coil 107 is incorporated into the middle leg 101a. The coil 107 is wound beforehand in a predetermined shape, and the insulating paper 103 and the insulating paper 104 are wound around the coil 107. Then, the spacer 106 is placed in the gap 108 partitioned by the insulating paper 105, and the end surfaces of the outer legs 101b and 101c and the corresponding opposing surfaces of the I-type core 102 are joined.

  As described above, in the embodiment disclosed in Patent Document 2, the spacer 106 having substantially the same shape as the gap 108 partitioned by the insulating paper 105 is inserted into the gap 108. Generation of noise due to vibration can be prevented. Further, since the spacer 106 is only inserted into the gap 108, the manufacturing process of the reactor is simplified and the work is not complicated.

  However, in the above-described method, the size of the spacer 106 varies, and if the thickness is too thick, the end surfaces of the outer legs 101b and 101c and the I-type core 102 are joined when the E-type core 101 and the I-type core 102 are joined. There is a problem in that a gap is formed between the corresponding opposing surfaces of each other and bonding cannot be performed. In addition, if the thickness dimension is too thin, vibrations of the E-type core 101 and the I-type core 102 cannot be suppressed, and in addition, the E-type core 101 and the I-type core 102 hit the spacer 106 due to vibration, and new vibrations are generated. There was a problem of becoming a noise source.

Therefore, in order to form the spacer 106, high dimensional accuracy is required, and there is a problem that the spacer 106 becomes expensive. In addition, there is a method in which the thickness of the spacer 106 is made thin in advance and is fixed using an adhesive, but the process of applying / drying the adhesive is added to the manufacturing process of the reactor 100, and the work is complicated. In addition, there is a problem that the occurrence of cracks in the core due to the difference in thermal expansion coefficient between the adhesive and the core is a concern.
Japanese Unexamined Patent Publication No. 2004-235462 (pages 4-5, FIG. 1) JP 2004-140055 A (page 3, FIGS. 1 to 4)

  The present invention solves the above-described problems, and by inserting a spacer into the gap formed in the core by a simple method and firmly fixing the spacer to the core, the vibration and noise generated in the gap can be reliably ensured. The purpose is to prevent.

In order to solve the above-mentioned problems, the present invention relates to a first aspect of the invention, a core formed by joining a first core and a second core, a coil wound around the core, and the first core. In the reactor including a gap formed between the first core and the second core, and a spacer inserted in the gap, the spacer includes a convex portion at an upper portion and a lower portion to form the gap. Each of the first core and the second core includes a concave portion that fits with the convex portion of the spacer.

  In the invention relating to claim 2, the shape of the convex portion provided in the spacer is formed such that the tip portion is larger than the base end portion of the convex portion, and the first core and the second core are formed. Each of the concave portions provided in the above is characterized in that the bottom portion is formed to be larger than the inlet portion of the concave portion.

Furthermore, the invention relating to claim 3 is characterized in that the gap is formed in either the first core or the second core.

  The invention according to claim 1 and claim 2 is provided with protrusions in the vertical direction of the spacer inserted into the gap formed by the first core and the second core, and the first core and the second core A concave portion that fits with the convex portion provided in the spacer is provided in a portion where the gap is formed. If the convex part of the spacer is formed so that the tip part is larger than the base end part, and the first core and the second concave part are formed so that the bottom part is larger than the inlet part, the first core and After joining the second core, the spacer is press-fitted into the gap so that the convex part of the spacer and the concave part of the core are engaged with each other, and the first core and the second core are used without using an adhesive. The spacer can be firmly fixed.

  Thereby, vibration generated in the gap and noise caused by the vibration can be suppressed. In addition, since the spacer is fixed by press-fitting without using an adhesive, it is possible to avoid the phenomenon of causing damage to the core such as cracks due to the difference in thermal expansion coefficient between the adhesive and the core material, and At the time of manufacturing the reactor, it is only necessary to press-fit a spacer into the gap without using an adhesive, so that it is possible to reduce the complexity of work such as application and drying of the adhesive and reduce the number of manufacturing steps.

  In the invention according to claim 2, the gap is provided in the first core or the second core. A coil formed by winding an electric wire a predetermined number of times is inserted into the first core or the second core. If there is a gap in the coil at this time, a coil in which leakage magnetic flux from the gap exists in the vicinity of the gap Due to the eddy current loss generated in linkage with the eddy current and the eddy current loss generated in the core near the gap, heat is generated in the coil and core near the gap, and the reactor itself is overheated. Providing the gap in the first core or the second core eliminates the gap in the coil, so that heat generation due to eddy current loss can be suppressed.

  Embodiments of the present invention will be described below in detail with reference to the accompanying drawings. As an embodiment, a reactor used for an air conditioner or the like and used for power factor improvement or the like, and a reactor having an EI type core will be described as an example.

  FIG. 1 is an explanatory diagram of a reactor according to the present invention, in which (A) is a perspective view of the reactor, and (B) is a cross-sectional view taken along line A-A ′ in (A). 2 is an assembly explanatory view of the reactor according to the present invention, (A) is an explanatory view of coil insertion-core bonding, (B) is an external view of the spacer, and (C) is a cross-sectional view of a main part for explaining the insertion of the spacer. FIG. The reactor 10 includes an E-type core 1 that is a first core, an I-type core 2 that is a second core, a spacer 3, insulating paper 4, and a coil 5. Moreover, although not shown in figure, the baseplate for attaching the reactor 10 to an electric equipment, the terminal for connecting with the control board of an electric equipment, and a terminal block are each provided.

  The E-type core 1 is made of a magnetic material such as a silicon steel plate, has a substantially E-shape when viewed from the front, and has a predetermined depth dimension. The E-type core 1 includes a middle leg 1a provided at the center, outer legs 1b and 1c provided on both sides thereof, and a connecting part 1d for connecting them. As shown in FIG. 2 (A), the middle foot 1a is formed shorter than the outer feet 1b and 1c, and a concave portion 1e is provided on the end face of the tip portion. The shape of the recess 1e is such that the width continuously widens from the end surface of the tip portion of the middle leg 1a like an inclined surface 1e ', and the width dimension w1' on the tip portion side of the recess 1e is the lower end. It is smaller than the width dimension w2 ′ on the part side (w1 ′ <w2 ′).

  The I-type core 2 is formed of a magnetic material such as a silicon steel plate and has a substantially rectangular parallelepiped shape with a predetermined dimension. A concave portion 2a is provided at the center of the lower surface of the I-type core 2, and the shape thereof is continuously widened from the lower surface of the I-type core 2 upward as an inclined surface 2a '. The width dimension w1 ′ on the lower surface side is smaller than the width dimension w2 ′ on the upper end side (w1 ′ <w2 ′). Therefore, the shape of the concave portion 2a is the same as that of the concave portion 1e provided in the middle leg 1a of the E-type core 1, and this is inverted 180 ° and provided in the I-type core 2.

  As shown in FIG. 2A, the end surfaces of the outer legs 1b and 1c of the E-type core 1 are joined to the corresponding surfaces of the I-type core 2 by welding or the like to form a magnetic path. Further, a gap 6 is formed by the tip of the middle leg 1a of the E-type core 1 and the corresponding surface of the I-type core 2 as shown in FIG. The gap 6 is provided to adjust the magnetic saturation characteristic of the reactor 10.

  The gap 6 has a width dimension of w3 ′ which is the width dimension of the middle leg 1a of the E-type core 1 and a height dimension of t1 ′ which is the distance between the end face of the tip of the middle leg 1a and the lower surface of the I-type core 2. Has been. The distance between the lower end of the recess 1e provided in the middle leg 1a and the upper end of the recess 2a provided in the center of the I-type core 2 is set to t2 '.

  The spacer 3 is formed of a resin material having hardness that suppresses vibration and heat resistance. The spacer 3 has the same depth dimension as the E-type core 1 and the I-type core 2, and protrudes upward and downward from the base 3 c having a rectangular shape with a predetermined width dimension w 3 and thickness dimension t 1. Portions 3a and 3b are formed. The convex portions 3a and 3b are formed so that the width dimension continuously expands upward / downward like an inclined surface 3a '' and an inclined surface 3b '', respectively. The width dimension w1 is smaller than the width dimension w2 of the upper surface 3a ′ of the convex portion 3a and the lower surface 3b ′ of the convex portion 3b (w1 <w2).

  The coil 5 is formed by winding an insulated wire, a so-called magnet wire, in which a polyester insulating coating is provided on a conductor such as copper in a predetermined number of times / shape. An insulating paper 5 made of an insulating material is wound around the coil 5 at a location where it contacts the E-type core 1 and the I-type core 2.

  The assembly method and procedure of the reactor 10 will be described with reference to FIG. First, the coil 5 having the insulating paper 4 wound around the middle leg 1a of the E-type core 1 is inserted. Next, the E-type core 1 and the I-type core 2 are assembled and joined by welding or the like. At this time, a gap 6 is formed between the middle leg 1 a of the E-type core 1 and the I-type core 2. Next, the spacer 3 is inserted into the gap 6, terminals (not shown), a terminal block and a bottom plate are attached, and the varnish is impregnated to complete.

  In the configuration described above, when current flows through the reactor 10, electromagnetic vibration increases in the gap 6 due to concentration of magnetic flux. This electromagnetic vibration is a vibration in which the middle leg 1a of the E-type core 1 and the I-type core 2 are repeatedly attracted to and protrude from each other, and noise is generated due to this vibration. Accordingly, the spacer 3 is provided with the concave portions 1e and 2a in the end surface of the tip portion of the middle leg 1a of the E-type core 1 and the central portion of the lower surface of the I-type core 2, and the convex portions 3a and 3b having shapes corresponding thereto. Is inserted into the gap 6, and the E-type core 1, the middle foot 1 a and the I-type core 2 are mechanically and firmly joined to suppress vibration and suppress generation of noise.

Next, the principle and effect of vibration / noise suppression according to this embodiment will be described with reference to FIGS. After inserting the coil 5 into the E-type core 1 and joining the I-type core 2, a gap 6 is formed between the middle leg 1 a of the E-type core 1 and the I-type core 2. The dimension is determined so that the shape of the gap 6 is the same as the shape of the spacer 3. More specifically, the dimensions of the corresponding portions of the spacer 3 and the gap 6 are dimensional relationships as shown in the following expression.

w1 = w1 ′ (1) w1 <w2 (6)
w2 = w2 ′ (2) w1 ′ <w2 ′ (7)
w3 = w3 ′ (3)
t1 = t1 ′ (4)
t2 = t2 ′ (5)

The spacer 3 is inserted into such a gap 6. Since the gap 6 and the spacer 3 have the same size and shape as shown in the equations (1) to (7), the spacer 3 is inserted into the gap 6. At that time, the spacer 3 is inserted while applying a force, that is, press-fitted. As a result, the contact pressure between the convex portion 3b of the spacer 3 and the concave portion 1e of the E-type core 1 and the convex portion 3a of the spacer 3 and the concave portion 2a of the I-type core 2 is increased. The core 2 is firmly joined.

  Further, the inclined surface 3 a ″ on the convex portion 3 a of the spacer 3 and the inclined surface 3 b ″ on the convex portion 3 b are expressed by Equation (6), the inclined surface 1 e ′ in the concave portion 1 e of the E-type core 1, and the concave portion 2 a of the I-type core 2. Since the inclined surface 2a ′ in FIG. 3 has the dimensional relationship of the expression (7), the protrusions 3a and 3b of the spacer 3 and the recesses 1e of the E-type core 1 and the recesses 2a of the I-type core 2 move in directions away from each other. Therefore, the spacer 3 and the gap 6 have a so-called tenon and tenon relationship.

  Therefore, when the spacer 3 vibrates so that the middle leg 1a of the E-type core 1 and the I-type core 2 in the gap 6 are attracted to each other, the thickness of the spacer 3 is not limited, and the spacer 3 vibrates in the direction in which it protrudes from each other. In some cases, the convex portions 3a and 3b of the spacer 3 are fitted into the concave portion 1e of the E-type core 1 and the concave portion 2a of the I-type core 2 so as to regulate the vibration. As a result, generation of noise due to vibration can be prevented.

  3A and 3B are views showing another embodiment of the reactor according to the present invention, in which FIG. 3A is a perspective view of the reactor, FIG. 3B is a cross-sectional view taken along line BB ′ in FIG. It is principal part sectional drawing explaining these. The reactor 20 differs from the first embodiment in the shape of the recesses provided in the E-type core and the I-type core, the position where the gap is formed, and the shape of the spacer. In addition, since it is the same as that of Example 1 about the part other than the above, the same number is attached | subjected and the description is abbreviate | omitted.

  The E-type core 21 that is the first core is formed of a magnetic material such as a silicon steel plate, has a substantially E-shape when viewed from the front, and has a predetermined depth dimension. The E-shaped core 21 includes a middle foot 21a provided at the center, outer feet 21b and 21c provided on both sides thereof, and a connecting portion 21d for connecting them. As shown in FIG. 2 (A), the middle foot 21a is provided with a recess 21e on the end surface of the tip. The shape of the concave portion 21e is such that the width continuously widens from the end surface of the distal end portion of the middle leg 1a like an inclined surface 21e ', and the width dimension w1' on the distal end side of the concave portion 21e is the lower end. It is smaller than the width dimension w2 ′ on the part side (w1 ′ <w2 ′).

  The I-type core 22 as the second core is formed of a magnetic material such as a silicon steel plate and has a substantially rectangular parallelepiped shape with a predetermined dimension. A gap 22b having a rectangular cross section with a height dimension t1 'and a width dimension w4' is provided at the center of the lower surface of the I-type core 22, and a recess 22a is provided at the center of the upper end thereof. The shape of the recess 22a is such that the width continuously increases along the inclined surface 22a ′ from the upper end of the cavity 22b, and the width dimension w1 ′ on the lower surface side is the width on the upper end side. It is smaller than the dimension w2 ′ (w1 ′ <w2 ′). Therefore, the shape of the recess 22a is the same as that of the recess 21e provided in the middle leg 21a of the E-type core 21, and this is inverted 180 ° and provided in the I-type core 22. Further, the width dimension w4 ′ of the gap 22b is set so that the flow of magnetic flux flying from the middle leg 21a of the E-type core 21 to the I-type core 22 without passing through the magnetic path, that is, the so-called minor loop, is suppressed. The dimension is slightly larger than the width dimension w3 ′.

  As shown in FIG. 3C, the end surfaces of the outer legs 21b and 21c of the E-type core 21 are joined to the corresponding surfaces of the I-type core 22 by welding or the like to form a magnetic path. Further, the distal end portion of the middle leg 21a of the E-type core 21 and the gap 22b provided in the I-type core 22 are opposed to each other, and as shown in FIG. 3C, the recess 22a, the gap 22b, and the recess 21e. Thus, the spacer insertion portion 24 is formed. The spacer insertion portion 24 has a height dimension t2 '.

  The gap 22b is provided to adjust the magnetic saturation characteristic of the reactor 20.

  The spacer 23 is formed of a resin material having hardness that suppresses vibration and heat resistance. The spacer 23 has the same depth dimension as the E-type core 21 and the I-type core 22, and protrudes upward and downward from the base portion 23 c having a rectangular shape with a predetermined width dimension w 4 and thickness dimension t 1. Portions 23a and 23b are formed. The convex portions 23a and 23b are formed so as to continuously increase in width as inclining surfaces 23a '' and sloping surfaces 23b '' upward / downward, respectively. The width dimension w1 is smaller than the width dimension w2 of the upper surface 23a ′ of the convex portion 23a and the lower surface 23b ′ of the convex portion 23b (w1 <w2).

  In the configuration described above, when a current flows through the reactor 20, electromagnetic vibration increases in the gap 22 due to the concentration of magnetic flux. This electromagnetic vibration is a vibration in which the middle leg 21a of the E-type core 21 and the I-type core 22 are repeatedly pulled and pushed away from each other, and noise is generated due to this vibration. Therefore, the spacer insertion portion 24 is formed by the concave portion 21e provided in the E-type core 21, the concave portion 22a provided in the I-type core 22 and the gap 22b, and the convex portions 23a and 23b having shapes corresponding thereto are vertically moved. By inserting the provided spacer 23 into the spacer insertion portion 24, the E-type core 21, the middle foot 21 a, and the I-type core 22 are mechanically firmly joined to suppress vibration and suppress noise generation.

  Further, by providing the gap 22 b in the I-type core 22, no gap is present in the coil 5. Normally, when a gap is provided, leakage magnetic flux is unavoidable. When this gap exists in the coil, the leakage magnetic flux from the gap is linked to the coil existing in the vicinity of the gap. Due to the loss and eddy current loss generated in the core near the gap, there is a problem that the coil or core near the gap generates heat and the reactor itself is overheated. In this configuration, since the gap 22b does not exist in the coil 5, the leakage magnetic flux from the gap 22b does not interlink with the coil 5, and heat generation in the gap 22 can be suppressed.

Next, the principle and effect of suppressing vibration and noise and preventing heat generation due to leakage magnetic flux from the gap will be described with reference to FIG. After the coil 5 is inserted into the E-type core 21, the I-type core 22 is joined. A recess 22a and a gap 22b are respectively formed in the I-type core 22, and a spacer insertion portion 24 is formed together with a recess 21e provided in the middle leg 21a of the E-type core 21 facing the gap 22b. The dimension is determined so that the shape of the spacer insertion portion 24 is the same as the shape of the spacer 23. More specifically, the dimensions of the corresponding portions of the spacer 23 and the spacer insertion portion 24 are set to have a dimensional relationship as shown in the following expression.

w1 = w1 ′ (8) w1 <w2 (13)
w2 = w2 ′ (9) w1 ′ <w2 ′ (14)
w4 = w4 ′ (10) w3 ′ <w4 ′ (15)
t1 = t1 ′ (11)
t2 = t2 ′ (12)

The spacer 23 is inserted into such a gap insertion portion 24. Since the gap insertion portion 24 and the spacer 23 have the same size and shape as shown in the equations (8) to (14), the spacer 23 is inserted into the gap. When inserting into the insertion part 24, it inserts, or press-fits, while applying force to the spacer 23 with a machine or the like. Thereby, the convex part 23b of the spacer 23 and the concave part 21e of the E-type core 21 and the convex part 23a of the spacer 23 and the concave part 22a of the I-type core 22 are brought into close contact with each other and firmly joined.

  In addition, the inclined surface 23 a ″ in the convex portion 23 a of the spacer 23 and the inclined surface 23 b ″ in the convex portion 23 b are expressed by Equation (13), the inclined surface 21 e ′ in the concave portion 21 e of the E-type core 21, and the concave portion 22 a of the I-type core 22. Since the inclined surface 22a ′ in FIG. 14 has the dimensional relationship of the formula (14), the protrusions 23a and 23b of the spacer 23 and the recesses 21e of the E-type core 21 and the recesses 22a of the I-type core 22 move away from each other. Therefore, the spacer 23 and the spacer insertion portion 24 have a so-called tenon and tenon relationship.

  Therefore, when the spacer 23 vibrates so that the middle leg 21a of the E-type core 21 and the I-type core 22 are attracted to each other in the spacer insertion portion 24, the thickness of the spacer 23 is not limited, and the direction in which the spacer 23 protrudes from each other. Also when vibrating, the convex portions 23a and 23b of the spacer 23 are fitted into the concave portion 21e of the E-type core 21 and the concave portion 22a of the I-type core 22 so as to restrict the vibration. As a result, generation of noise due to vibration can be prevented.

  Further, since the gap 22 b is provided in the I-type core 22, the middle leg 21 a of the E-type core 21 exists in the coil 5. As a result, the leakage magnetic flux from the gap 22b is linked to the coil 5 to cause eddy current loss and prevent the reactor 20 from being overheated due to heat generation.

  In addition, as shown in Formula (15), the width dimension w4 ′ of the gap 22b is made larger than the width dimension w3 ′ of the middle leg 21a of the E-type core 21 from the middle leg 21a to the I-type core 22. This is to prevent the occurrence of a short circuit in the flow of magnetic flux, a so-called minor loop.

  As described above, according to the present invention, the protrusions are provided in the vertical direction of the spacer inserted into the gap formed by the first core and the second core, and the gap between the first core and the second core is provided. A concave portion that fits with the convex portion provided in the spacer is provided in the portion forming the. If the convex part of the spacer is formed so that the tip part is larger than the base end part, and the first core and the second concave part are formed so that the bottom part is larger than the inlet part, the first core and After joining the second core, the spacer is press-fitted into the gap so that the convex part of the spacer and the concave part of the core are engaged with each other, and the first core and the second core are used without using an adhesive. The spacer can be firmly fixed.

  Thereby, vibration generated in the gap and noise caused by the vibration can be suppressed. In addition, since the spacer is fixed by press-fitting without using an adhesive, it is possible to avoid the phenomenon of causing damage to the core such as cracks due to the difference in thermal expansion coefficient between the adhesive and the core material, and At the time of manufacturing the reactor, it is only necessary to press-fit a spacer into the gap with a machine without using an adhesive, so that the complexity of work can be suppressed and the number of manufacturing steps can be reduced.

  A gap is provided in the first core or the second core. A coil formed by winding a wire a predetermined number of times is inserted into the first core or the second core. If there is a gap in the coil at this time, the leakage magnetic flux from the gap is linked to the coil. There is a problem that heat is generated by the generated eddy current loss and the reactor itself is overheated. Providing the gap in the first core or the second core eliminates the gap in the coil, so that heat generation due to eddy current loss can be suppressed.

  In the embodiment described above, the reactor including the core formed by joining the E-type core and the I-type core and providing a gap at one place of the joint portion has been described, but the invention is not limited thereto. For example, a core is formed by combining two cores, such as two E-type cores joined or T-type cores and U-type cores joined, and a gap is formed using the joints. The present invention can be applied if it exists. In addition, in the case of a reactor having a core having gaps at two or more joint portions, or even in a reactor having a core in which a plurality of cores are combined to provide a plurality of gaps, the same applies. it can.

  In the embodiment described above, the case where the gap is formed of a heat-resistant resin material has been described. However, the present invention is not limited to this, and is a non-magnetic material having high hardness and heat resistance. If it is. Also, the shape of the spacer is not limited to the shape described in the embodiment. For example, when the shape of the convex portion vibrates in the direction in which the cores protrude from each other like a round shape or a T shape, the vibration is regulated. Any shape can be used. Furthermore, the shape and size of the convex portions above and below the spacer may be different.

It is explanatory drawing of the reactor which is an Example of this invention, (A) is a reactor perspective view, (B) is AA 'sectional drawing in (A). It is assembly explanatory drawing of the reactor in the Example of this invention, (A) is coil insertion-core joining explanatory drawing, (B) is a spacer external view, (C) is principal part sectional drawing explaining spacer insertion. It is explanatory drawing of the reactor in the other Example of this invention, (A) is a perspective view of a reactor, (B) is BB 'sectional drawing in (A), (C) is the important point explaining insertion of a spacer FIG. It is explanatory drawing of the conventional reactor, (A) is a reactor perspective view, (B) is a reactor exploded view. It is a figure which shows the E-type core in the conventional reactor, (A) is an insulation paper mounting perspective view, (B) is a spacer mounting perspective view.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 E type core 1a Middle leg 1e Recess 1e 'inclined surface 2 I type core 2a Recess 2a' inclined surface 3 Spacer 3a Convex 3a '' inclined surface 3b Convex 3b '' inclined surface 5 Coil 6 Gap 10 Reactor 20 Reactor 21 E-type core 21a Middle foot 21e Recessed portion 21e 'Inclined surface 22 I-type core 22a Recessed portion 22b Gap 22a' Inclined surface 23 Spacer 23a Convex portion 23a '' Inclined surface 23b Convex portion 23b '' Inclined surface 24 Spacer insertion portion

Claims (3)

A core formed by joining the first core and the second core; a coil wound around the core; a gap formed between the first core and the second core; In the reactor provided with a spacer to be inserted into
The spacer includes a convex portion at an upper portion and a lower portion, and a concave portion that fits the convex portion of the spacer in each of the first core and the second core that form the gap. .     The convex part provided in the spacer is formed so that the tip part is larger than the base end part of the convex part, and the concave part provided in each of the first core and the second core is the same. The reactor according to claim 1, wherein a bottom portion is formed to be larger than an inlet portion of the concave portion.     The reactor according to claim 1, wherein the gap is formed in either the first core or the second core.

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