JP2015118957A - Resin impregnated reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin impregnated reactor that secures the insulation distance between a core and a coil, while having an improved waterproof property.SOLUTION: A resin impregnated reactor includes a core 2 having a leg 3, and a coil 1 mounted to the leg 3 of the core 2. A surface of the coil 1 is covered with a first insulation tape 4 having a rein impregnation property. An insulation sheet 5 is arranged on a surface of the insulation tape that covers the coil 1. A locating piece 5a that comes into contact with a core 2 is arranged on the insulation sheet 5. An end of the insulation sheet 5 is covered with a second insulation tape 6. The first insulation tape 4 and the second insulation tape 6 are impregnated with resin. The whole shape of the coil 1 is in a loop, and the leg 3 of the core 2 is inserted into an opening 1a in the center of the loop, while the first insulation tape 4 passes through the opening 1a in the center of the loop from the outside of the loop, to be wound around the whole surface of the coil 1. The locating piece 5a is formed by having a cut in a part of the insulation sheet 5.

Description

  The present invention relates to a resin-impregnated reactor having improved waterproof performance.

  Conventionally, there is a type in which a coil is molded as a waterproof reactor, but it is used only for special applications because of the high cost of the resin and equipment. In addition, there is a product in which the entire reactor is covered with the finishing impregnating agent by immersing the reactor in the finishing impregnating agent, but depending on the temperature change, the impregnating agent may crack and impair the waterproofness.

  Therefore, recently, as shown in Patent Document 1, a reactor in which a fibrous tape is wound around a coil and the tape is impregnated with a resin has been proposed.

JP 2013-206943 A

  Certainly, this type of reactor has the advantage that the resin is surely impregnated around the coil and the adhesiveness between the resin and the tape is good, so that there is little risk of cracking. However, even in this type of reactor, there is a problem that a sufficient insulation distance cannot be ensured between the coil and the core unless the positioning of both is performed accurately when the coil core is mounted. In particular, as the reactor becomes smaller, the allowable space between the coil and the core is reduced. Therefore, if the mounting positions of the two are shifted, there is a possibility that dielectric breakdown may occur in the portion where both are close to each other.

  Recently, reactors equipped with resin-impregnated coils have been adopted for applications such as in-vehicle and outdoor installations, but these reactors are required to have a high degree of waterproofness. However, if only a coil in which a tape is impregnated with a resin as in Patent Document 1 is used, water enters the gap between the coil and the core, and the insulation performance between the two deteriorates.

  The object of the present invention is to accurately position the core and the coil so as to secure an insulation distance between them and prevent water from entering between them, thereby improving the waterproof property. It is to provide a reactor.

The resin-impregnated reactor of the present invention has the following configuration.
(1) A core having legs and a coil attached to the legs of the core.
(2) A first insulating tape having a resin impregnation property and covering the surface of the coil.
(3) An insulating sheet disposed on the surface of the insulating tape covering the coil.
(4) A second insulating tape having resin impregnation properties and covering an end portion of the insulating sheet.
(5) A resin impregnated in each insulating tape.

  A positioning member that contacts the core may be provided on the coil. In that case, it is preferable that the positioning member is a positioning piece provided integrally with the insulating sheet. Preferably, the positioning piece is formed by cutting a part of the insulating sheet, the positioning piece of the insulating sheet is protruded from the coil surface, and a part other than the positioning piece is bent along the coil surface.

  As the core, an E-shaped split core having three legs and an I-shaped split core are combined into a Japanese character, and the coil is mounted on the center leg of the E-shaped split core. You can use what you have.

  The coil has a loop shape as a whole, and a core leg is inserted into the opening at the center of the loop, and the first insulating tape passes through the opening at the center of the loop from the outside of the loop. It is preferable to be wound around the entire surface.

  The insulating sheet can be wound around the surface of the coil having a loop shape from the outside of the loop through the opening at the center of the loop. In this case, the insulating sheets overlap on the coil surface, and the overlapped portion is covered with the second insulating tape.

  According to the present invention, the insulating sheet is attached to the resin-impregnated coil, the end portion of the insulating sheet is covered with the insulating tape having resin impregnation property, and the resin is impregnated in the portion. There is no gap for water immersion, and waterproofness is improved. In addition, when a positioning member such as a positioning piece provided on the insulating sheet is used to accurately position the coil and the core, the insulation distance between the core and the coil can be reliably ensured. .

The perspective view which shows the resin impregnation type | mold reactor of 1st Embodiment. The disassembled perspective view which shows the resin impregnation type | mold reactor of 1st Embodiment. The perspective view of the state which attached the insulating sheet to the coil in 1st Embodiment. In 1st Embodiment, the expansion perspective view of the state which mounted | wore the coil with the insulating sheet. In 1st Embodiment, the expansion perspective view of the state which coat | covered the edge part of the insulating sheet with the insulating tape. In 1st Embodiment, the expansion perspective view which removes an outer heat contraction tube and shows the connection state of a coil end part and a leader line. The expanded perspective view which decomposes | disassembles and shows the connection state of a coil edge part and a leader line in 1st Embodiment. The expansion perspective view which shows the modification 1 of the insulating sheet in 1st Embodiment. The expansion perspective view which shows the modification 2 of the insulating sheet in 1st Embodiment. The expansion perspective view which shows the modification 3 of the insulating sheet in 1st Embodiment.

[1. First Embodiment]
[1-1. Constitution]
Hereinafter, a first embodiment of the present invention will be specifically described with reference to the drawings. 1st Embodiment is comprised from the positioning piece which provided the positioning member integrally in the insulating sheet.

  As shown in FIGS. 1 and 2, the resin-impregnated reactor according to the present embodiment includes a core 2 having a leg portion 3 and a coil 1 attached to the leg portion 3 of the core 2. The coil 1 is a loop with a rounded rectangular shape, and the leg 3 of the core 2 is inserted into the opening 1a at the center of the loop. That is, the core 2 is a combination of an E-shaped divided core 2a having three legs 3 and an I-shaped divided core 2b in a Japanese character shape, and the coil 1 is the center of the E-shaped divided core 2a. It is attached to the leg part 3. The E-shaped split core 2a and the I-shaped split core 2b are screwed to the fixing plate 7 disposed on the back surface thereof, and are integrated.

  The surface of the coil 1 is covered with a first insulating tape 4 having resin impregnation properties. The first insulating tape 4 is wound around the entire surface of the coil 1 from the outside of the loop through the opening 1a at the center of the loop.

  An insulating sheet 5 made of insulating paper having resin impregnation property is disposed on the surface of the first insulating tape 4 that covers the coil 1. In this embodiment, as shown in FIG. 3, the insulating sheet 5 is arrange | positioned at each of the two long sides which the coil 1 of a rounded round rectangle opposes. Each insulating sheet 5 is formed by winding one insulating sheet 5 around the surface of the coil 1 from the outside of the loop through the opening 1a at the center of the loop.

  In this case, the insulating sheet 5 overlaps on the surface of the coil 1, and the overlapped portion is covered with the second insulating tape 6. The second insulating tape 6 is wound around the looped coil 1 from the outside of the loop toward the inside of the loop, and covers the overlapping portion of the end of the insulating sheet 5.

  Positioning pieces 5 a that protrude from the surface of the coil 1 are formed on the left and right ends of the insulating sheet 5. A portion of the insulating sheet 5 other than the positioning piece 5a is bent along the coil surface, and the core 2 is attached to a portion sandwiched between the two positioning pieces 5a. That is, as shown in FIG. 4, the positioning piece 5a contacts the side surface of the core 2 attached to the coil 1, and the positional relationship between the core 2 and the coil 1, particularly, the coil 1 and the core 2 having a rounded rectangular shape. The distance from the end of the is regulated.

  As shown in FIG. 5, the outer portion of the positioning piece 5 a in the insulating sheet 5, that is, the short side of the coil 1 is bent along the surface of the coil 1, and the portion is covered with the second insulating tape 6. ing. In particular, in this embodiment, the end portion of the insulating sheet 5 is overlapped on the surface of the coil 1, and the second insulating tape 6 is wound from the outside of the overlapped portion, and the overlapped portion is exposed. There is no coating.

  As the first insulating tape 4 having resin impregnation properties, it is preferable to use a cloth tape woven from a material excellent in heat resistance and flame retardancy such as meta-aramid fiber. As the insulating sheet 5, a material excellent in heat resistance and flame retardancy having resin impregnation properties such as insulating paper is preferable. The first insulating tape 4, the second insulating tape 6 and the insulating sheet 5 are impregnated with a resin generally called an insulating varnish. As the insulating varnish, an epoxy-based, silicone-based, polyester-based or phenol-based synthetic resin is used.

  As shown in FIGS. 6 and 7, a lead wire 10 is connected to the end 1 b of the coil 1 for connection to an external wiring. In a state where the lead wire 10 and the coil end 1b are electrically and mechanically connected by the butt sleeve 11, the insulating tape 12 for sealing is wound around the outer periphery of the coil end 1b for adjusting the outer diameter, Further, the inner heat shrinkable tube 13 and the outer heat shrinkable tube 14 are covered twice from above.

  Thus, the connection part of the coil end part 1b and the lead wire 10 which was waterproofed is wound around the coil 1 with the insulating tape and impregnated with resin with the insulating tape. It is fixed to. Therefore, even if a force is applied to the coil end 1b, the coil end 1b is not lifted from the surface of the coil 1 by being pressed by the insulating tape, and cracks are hardly generated in the impregnated and solidified resin.

[1-2. Effect]
According to the present embodiment having the above-described configuration, the outer periphery of the coil 1 is covered with the first insulating tape 4 and the first insulating tape 4 is impregnated with a resin such as an insulating varnish. The adhesion between the coil 1 and the coil 1 is improved, and the occurrence of cracks is prevented. In addition, in the present embodiment, since the insulating sheet 5 is disposed between the first insulating tape 4 and the core 2, higher insulating performance than the configuration in which the insulating tape 4 is simply wound. Can be secured. In this embodiment, the insulating sheet 5 is not only for ensuring insulation but also by providing a positioning piece on a part of the insulating sheet 5 to ensure accurate positioning between the coil 1 and the core 2 and to insulate them. Since the distance can be secured, the insulation performance is also excellent in that respect.

  When the insulating sheet 5 is disposed between the coil 1 and the core 2, a narrow gap is generated between these members, and there is a possibility that the waterproofness is lowered due to water entering the portion, but in this embodiment, By covering the end portion of the insulating sheet 5 with the second insulating tape 6, the gap can be closed and high waterproof performance can be ensured. In particular, in this embodiment, since the insulating sheet 5 is wound around the coil 1 so that the end portions thereof overlap, a gap is generated between the insulating sheets 5, but the gap is also formed by the second insulating tape 6. Since it is coated, it is excellent in waterproofness.

  A sufficient waterproofness can be secured by covering the connecting portion between the coil end portion 1b and the lead wire 10 with the inner and outer double heat-shrinkable tubes 13,14. In particular, the difference between the outer diameters of the coil end portion 1b and the lead wire 10 is adjusted by the sealing insulating tape 12, and the heat shrinkable tubes 13 and 14 are formed from the top, so that the amount of heat shrinkage of the tube is reduced by the coil. The end portion 1b and the lead wire 10 are substantially equal, and the adhesion of the tube is improved.

[2. Other Embodiments]
The present invention is not limited to the first embodiment, and includes other embodiments as follows.

(1) Although 1st Embodiment used what has three leg parts which have the E-shaped division | segmentation core 2a as a core, two of the U-shaped cores or I-shaped cores which combined the B shape. The present invention can also be applied to a reactor in which the coil 1 is mounted on the leg portion of the present invention.

(2) In the first embodiment, the first insulating tape 4 is wound around the coil 1 so as to pass from the outside to the inside of the loop. However, the covering structure of the coil surface by the first insulating tape 4 is not limited to this. The inner periphery and the outer periphery of the coil 1 may be covered with separate insulating tapes, or the first insulating tape 4 may be wound around the outer periphery of the coil 1 several times and then wound around the coil through the inside and outside of the loop.

(3) The insulating sheet 5 can be fixed to the surface of the coil 1 by means such as adhesion instead of being arranged so as to wind the coil 1. As the simplest configuration, when the first insulating tape 4 is wound around the coil 1, a part of the insulating sheet 5 can be sandwiched and fixed between the overlapping insulating tapes 4.

(4) The shape of the positioning piece 5a is not limited to that shown in the figure, and can be protruded above the coil 1 as shown in FIG. 8, or can be protruded from the side as shown in FIG. The insulating sheet 5 does not necessarily have to be wound around the entire coil, and may have a shape that covers a part of the coil 1 as shown in FIG. Furthermore, it is possible to prevent the core 2 from moving on the insulating sheet 5 by folding the end portion of the insulating sheet 5 to make the wall thickness larger than the portion where the core 2 is mounted. In this case, by providing a tape having insulation performance such as an aramid fiber tape or the like between the outer side of the first insulating tape 4 or between the core 2 and the first insulating tape 4, insulation between the coil 1 and the core 2 is achieved. Secure.

(5) As the first insulating tape 4, cloth-like tape made of synthetic fibers such as polyester fiber, aramid fiber, polyamide fiber, polyimide fiber, glass fiber, natural fiber, nonwoven fabric, paper, etc., or open cell The porous resin tape which has can be used. The material of the insulating sheet 5 is preferably a resin-impregnated material such as insulating paper, or a material that is compatible with the resin, but the synthetic resin sheet is cut to form the positioning piece 5a, or like a sheet. It can also be formed by a thin molded product. As the second insulating tape 6, an insulating tape can be used as appropriate, for example, an adhesive tape having insulating properties and waterproof properties is used, or the same material as the first insulating tape is used. It can also be used.

(6) The connection between the coil end 1b and the lead wire 10 is not limited to the double structure of the heat-shrinkable tube, and various configurations can be adopted according to the required waterproofness and weather resistance. For example, it is possible to cover the outer periphery of the connection location with an insulating tape impregnated with resin and then cover the heat shrink tube, or to fill the periphery of the connection location with a molten resin and solidify it.

(7) Although 1st Embodiment comprised the positioning member from the positioning piece 5a which provided the insulating sheet, the positioning member can also be comprised from a member different from an insulating sheet. A U-shaped clip-like member is fitted to the end of the insulating sheet 5 in the coil 1 to form a positioning member, or the second insulating tape 6 covering the end of the insulating sheet 5 is wound several times thickly. Thus, it is possible to project from the surface of the coil 1 and position the core at the projecting portion.

(8) There is an advantage that a high waterproof property can be obtained only by covering the end portion of the insulating sheet 5 with the second insulating tape 6 without providing the positioning member.

DESCRIPTION OF SYMBOLS 1 ... Coil 1a ... Opening part 1b ... Coil end part 2 ... Core 2a ... E-shaped division | segmentation core 2b ... I-shaped division | segmentation core 3 ... Leg part 4 ... 1st insulating tape 5 ... Insulation sheet 5a ... Positioning piece 6 ... Second insulating tape 7 ... fixing plate 10 ... lead wire 11 ... butting sleeve 12 ... insulating tape 13 ... inner heat shrink tube 14 ... outer heat shrink tube

Claims (8)

A core having legs,
A coil attached to the leg of the core;
A first insulating tape having resin impregnation properties and covering the surface of the coil;
An insulating sheet disposed on the surface of the insulating tape covering the coil;
A second insulating tape having resin impregnation properties and covering an end of the insulating sheet;
A resin impregnated in each of the insulating tapes;
A resin-impregnated reactor characterized by having:   The resin-impregnated reactor according to claim 1, wherein the coil is provided with a positioning member that comes into contact with the core.   The resin-impregnated reactor according to claim 2, wherein the positioning member is a positioning piece provided integrally with the insulating sheet.   The positioning piece is formed by providing a cut in a part of the insulating sheet, the positioning piece of the insulating sheet protrudes from the coil surface, and a portion other than the positioning piece is bent along the coil surface. The resin-impregnated reactor according to claim 3.   The core is a combination of an E-shaped split core having three legs and an I-shaped split core in a Japanese character shape, and the coil is mounted on the center leg of the E-shaped split core. The resin-impregnated reactor according to any one of claims 1 to 4, wherein the reactor is impregnated.   The coil has a loop shape as a whole, and a core leg is inserted into the opening at the center of the loop, and the first insulating tape passes through the opening at the center of the loop from the outside of the loop. The resin-impregnated reactor according to any one of claims 1 to 5, wherein the resin-impregnated reactor is wound around the entire surface of the resin.   The resin-impregnated reactor according to any one of claims 1 to 6, wherein the insulating tape having resin impregnation property is meta-aramid fiber or glass fiber.   The coil end portion of the coil and the connecting portion of the lead wire connected to the coil end portion are covered with a plurality of heat-shrinkable tubes which are overlapped with each other. The resin-impregnated reactor according to Item.

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