JP2018198301A - Coil, method for forming coil, and reactor - Google Patents

Abstract

To provide a firm coil in which much more varnish is stored in a gap between wires with a coil prepared by edgewise bending work using a flat wire with enamel coat.SOLUTION: A coil 51 is formed by winding a flat rectangular wire 50 with enamel coat. The flat rectangular wire 50 is arranged with at least partial gap 60 in a circumferential direction of the coil with each other and into the at least partial gap an insulation member 70a is inserted. In addition, an insulation assembly 75 including a coupling unit coupled with the insulation member 70a is provided. The insulation assembly 75 includes a radiation fin 76 and an open hole 77. Refrigerant flows through the open hole 77.SELECTED DRAWING: Figure 5A

Description

  The present invention relates to a coil, a method for forming a coil, and a reactor.

  When creating a coil by winding a wire, it is necessary to bend the wire at the corner of the coil. For this reason, the thickness of the wire rod in the corner portion increases on the inner peripheral surface side of the coil and decreases on the outer peripheral surface side. As a result, a gap is formed between adjacent wires on the outer peripheral surface side of the coil. In the case of a wire having a rectangular cross section, for example, a flat wire, the gap becomes larger as the flat wire has a larger plate thickness and a smaller coil bending radius. For this reason, even after the coil is impregnated with the varnish, the varnish hardly stays in the gap, and it may be difficult to fix the adjacent wires to each other. In particular, in a coil created by edgewise bending, a gap may be generated between adjacent wires.

  In order to prevent such a phenomenon, a technique of pressing a coil after winding a wire is known in the prior art (see, for example, Patent Document 1). In the case of press working, the gap between adjacent wires on the outer peripheral surface side of the coil becomes small, and the varnish tends to stay in the gap.

JP 2013-121210 JP

  However, when pressing, it is necessary to be careful not to peel off the coating previously applied to the wire, and the number of work steps increases due to the pressing. Further, depending on the shape of the coil or the like, it may be difficult to perform press working. In addition, there may be a situation where the coating of the wire is deteriorated or peeled off by pressing.

  Therefore, there is a demand for a robust coil and a method for forming the coil that allows the varnish to remain in the gap without performing pressing, and a reactor including such a coil.

  According to a first aspect of the present disclosure, in a coil formed by winding a rectangular wire with an enamel coating, the rectangular wire is disposed with a gap at least partially in the circumferential direction of the coil. A coil is provided in which an insulating member is inserted in the partial gap.

  In the first aspect, an insulating member is inserted into at least a partial gap of the coil. For this reason, when impregnating a varnish, a varnish stays in a clearance gap and a coil can be formed more firmly. Furthermore, since it is not necessary to press work, it is possible to prevent the coating from deteriorating or peeling off.

  These and other objects, features and advantages of the present invention will become more apparent from the detailed description of exemplary embodiments of the present invention illustrated in the accompanying drawings.

It is a perspective view of the reactor containing the coil based on 1st embodiment. It is an expansion perspective view of one coil. FIG. 3 is a cross-sectional view of the coil taken along line A1-A2 of FIG. FIG. 3 is a cross-sectional view of the coil taken along line B1-B2 in FIG. It is other sectional drawing similar to FIG. 3A. It is other sectional drawing similar to FIG. 3B. It is sectional drawing seen along line A1-A2 of FIG. 2 of the coil in 1st embodiment. It is sectional drawing seen along line B1-B2 of FIG. 2 of the coil in 1st embodiment. It is other sectional drawing similar to FIG. 4A in 1st embodiment. It is other sectional drawing similar to FIG. 4B in 1st embodiment. It is sectional drawing in the linear part of the coil in 2nd embodiment. It is sectional drawing in the corner part of the coil in 2nd embodiment. It is a front view of a coil. It is a figure which shows the magnetic flux density when the electrical angle of the reactor shown by FIG. 1 is (pi) / 6. It is the elements on larger scale of FIG. 7A. It is an enlarged view of an iron core and a coil shown in FIG. 7A. It is a figure similar to FIG. 8A in a prior art. It is an expansion perspective view of the coil in 3rd embodiment. It is sectional drawing of the reactor in 4th embodiment.

Embodiments of the present invention will be described below with reference to the accompanying drawings. In the following drawings, the same members are denoted by the same reference numerals. In order to facilitate understanding, the scales of these drawings are appropriately changed.
In the following description, a three-phase reactor may be mainly described as an example. However, the application of the present disclosure is not limited to a three-phase reactor, and can be widely applied to a multiphase reactor in which a constant inductance is required for each phase. In addition, the reactor according to the present disclosure is not limited to those provided on the primary side and the secondary side of the inverter in industrial robots and machine tools, and can be applied to various devices.

  FIG. 1 is a perspective view of a reactor including a coil according to the first embodiment. Further, FIG. 7A is a diagram showing the magnetic flux density when the electrical angle of the reactor shown in FIG. 1 is π / 6. As shown in FIGS. 1 and 7A, the reactor 5 includes an annular outer peripheral core 20 and three iron core coils 31 to 33 that are magnetically coupled to the outer peripheral core 20. In FIG. 1 and FIG. 7A, iron core coils 31 to 33 are disposed inside the outer peripheral iron core 20. These iron core coils 31 to 33 are arranged at equal intervals in the circumferential direction of the reactor 5.

  As can be seen from the drawings, each of the iron core coils 31 to 33 includes iron cores 41 to 43 extending in the radial direction of the outer peripheral iron core 20 and coils 51 to 53 wound around the iron core. The outer ends in the radial direction of the iron cores 41 to 43 are in contact with the outer peripheral core 20 or are formed integrally with the outer peripheral core 20.

  Further, the inner ends in the radial direction of the iron cores 41 to 43 are located in the vicinity of the center of the outer peripheral iron core 20. In the drawing, the inner ends in the radial direction of the iron cores 41 to 43 converge toward the center of the outer peripheral iron core 20, and the tip angle is about 120 degrees. And the radial direction inner side edge part of the iron cores 41-43 is mutually spaced apart via the gap which can be connected magnetically. In the configuration shown in FIG. 1, since the three iron core coils 31 to 33 are surrounded by the outer peripheral iron core 20, the magnetic field generated from the coils 51 to 53 does not leak outside the outer iron core 20.

  FIG. 2 is an enlarged perspective view of one coil. Although the coil 51 is shown in FIG. 2, the other coils 52 and 53 have substantially the same configuration, and thus the description of the other coils 52 and 53 is omitted. The coil 51 is formed by winding a single conductive wire 50 having a rectangular cross section, that is, a flat wire 50 at least once. It is assumed that a film, such as an enamel film, is formed on the surface of the wire 50 in advance. As can be seen from FIG. 2, the coil 51 is wound in a substantially rectangular shape. As a result, the coil 51 has four corner portions C and four straight portions L formed between the corner portions C. ing.

  3A is a cross-sectional view of the coil taken along line A1-A2 in FIG. The inner peripheral surface 61 of the coil 51 is shown on the right side of FIG. 3A, and the outer peripheral surface 62 of the coil 51 is shown on the left side of FIG. 3A. Since the cross section of the flat wire 50 is rectangular, when the flat wire 50 is edgewise bent, the cross section of the flat wire 50 at the corner portion C of the coil 51 becomes trapezoidal as shown in FIG. 3A. Then, on the inner peripheral surface 61 side of the corner portion C of the coil 51, the adjacent rectangular wires 50 abut on each other. On the other hand, on the outer peripheral surface 62 side of the corner portion C of the coil 51, adjacent rectangular wires 50 are arranged with a gap 60 therebetween.

  3B is a cross-sectional view of the coil taken along line B1-B2 in FIG. As shown in FIG. 3B, the cross section of the flat wire 50 in the straight line portion L of the coil 51 remains rectangular. For this reason, on the inner peripheral surface 61 side and the outer peripheral surface 62 side in the linear portion L of the coil 51, the adjacent rectangular wires 50 are arranged with a gap 60 therebetween. Accordingly, the gap 60 in the linear portion L of the coil 51 extends between the outer peripheral surface 62 and the inner peripheral surface 61.

  In other words, the gap 60 is formed on the inner peripheral surface 61 corresponding to the straight portion L of the coil 51 and is formed over the entire outer peripheral surface 62 of the coil 51. Accordingly, it can be said that the coil 51 has a gap 60 extending at least partially in the circumferential direction of the coil 51.

  3C and 3D are other cross-sectional views similar to FIGS. 3A and 3B, respectively, of the coil after impregnating the varnish. In the case shown in FIGS. 3C and 3D, the varnish 80 does not stay in the gap 60 described above and does not completely fill the gap 60. For this reason, the fixed area of the varnish 80 is insufficient, and the adjacent flat wires 50 remain separated from each other on the outer peripheral surface 62 side. Therefore, in this case, it is difficult to form the coil 51 firmly. Further, since the adjacent rectangular wires 50 are separated from each other, noise and vibration may be generated when the reactor 5 is driven.

  In contrast, FIG. 4A is a cross-sectional view of the coil according to the first embodiment, taken along line A1-A2 in FIG. 4B is a cross-sectional view of the coil according to the first embodiment, taken along line B1-B2 of FIG. In FIG. 4A, an insulating member 70, for example, insulating paper is inserted into a gap 60 between the rectangular wires 50 adjacent to each other in the corner portion C of the coil 51. In FIG. 4B, a similar insulating member 70 is inserted in the gap 60 between the rectangular wires 50 adjacent to each other in the linear portion L of the coil 51. The entire insulating member 70 may be inserted into the gap 60, or a part of the insulating member 70 may protrude from the inner peripheral surface 61.

  When the insulating member 70 is inserted into the gap 60, a minute gap 60 a is formed between one flat wire 50 and one surface of the insulating member 70. Further, a minute gap 60 b is formed between the other surface of the insulating member 70 and the other flat wire 50. That is, by inserting the insulating member 70, one gap 60 is divided into two minute gaps 60a and 60b.

  4C and 4D are other cross-sectional views similar to FIGS. 4A and 4B, respectively, of the coil after impregnating the varnish. As shown in these drawings, when the coil 51 is impregnated into the varnish 80, the varnish 80 enters the two minute gaps 60a and 60b and stays there. For this reason, the gap 60 described above is almost completely filled.

  Therefore, the space between one flat wire 50 and one surface of the insulating member 70 and the space between the other surface of the insulating member 70 and the other flat wire 50 are firmly fixed. As a result, the coil 51 can be formed more firmly.

  The thickness of the insulating member 70 is determined according to the size of the gap 60 and the viscosity of the varnish so that the varnish 80 can remain in the two minute gaps 60a and 60b. Further, as the insulating member 70, a resin plate or the like may be used. Note that the insulating member 70 may be inserted only in a part of the plurality of gaps 60.

  Furthermore, in the first embodiment, since the adjacent rectangular wires 50 are fixed to each other, no noise or vibration is generated when the reactor 5 is driven. Furthermore, since it is not necessary to press the coil 51 after the coil 51 is formed, it is possible to avoid deterioration or peeling of the coating formed on the outer surface of the flat wire 50.

  FIG. 5A is a cross-sectional view of the linear portion of the coil according to the second embodiment. As shown in FIG. 5A, in the straight line portion L of the coil 51, the flat wires 50 are arranged in parallel with each other with a gap 60 therebetween. An insulating assembly 75 is disposed adjacent to the outer peripheral surface 62 of the coil 51.

  The insulating assembly 75 includes a coupling portion 74 having a surface to which at least one insulating member 70a is coupled. The insulating member 70 a is preferably a flat plate made of an insulating material that can be inserted between the flat wires 50. The insulating member 70 a of the insulating assembly 75 is preferably inserted into the gap 60 between the rectangular wire 50 from the outer peripheral surface 62 side of the coil 51. In this case, the insulating member 70a can be easily inserted into the gap 60. However, the insulating member 70 a of the insulating assembly 75 may be inserted into the gap 60 between the rectangular wire 50 from the inner peripheral surface 61 side of the coil 51.

  When the coil 51 is impregnated in the varnish 80 with the insulating assembly 75 disposed, the same effect as described above can be obtained. The insulating member 70a of the insulating assembly 75 shown in FIG. 5A is preferably equal to or greater than the width of the flat wire 50, so that the coil 51 can be formed more firmly.

  As shown in FIG. 5A, a plurality of heat radiation fins 76 may be provided on the other surface of the coupling portion 74. The coupling portion 74 and the heat radiating fins 76 are preferably formed from a material other than an insulating material, for example, a metal material. Thereby, the heat dissipation effect of the coil 51 can be enhanced when the reactor 5 including the coil 51 and the like is driven.

  Further, the coupling portion 74 is formed with a plurality of through holes 77 extending in parallel to the circumferential direction of the coil. In these through holes 77, a refrigerant flows from a refrigerant source (not shown), thereby further enhancing the heat radiation action of the coil 51.

  FIG. 5B is a cross-sectional view of a corner portion of the coil according to the second embodiment. As shown in FIG. 5B, on the inner peripheral surface 61 of the corner portion C of the coil 51, the flat wires 50 are in contact with each other, and no gap is formed. On the outer peripheral surface 62 of the corner portion C of the coil 51, the flat wires 50 are arranged with a gap 60 therebetween.

  An insulating assembly 75 ′ having the same configuration as the insulating assembly 75 described above is disposed adjacent to the outer peripheral surface 62 of the coil 51. The insulating member 70 b and the like of the insulating assembly 75 ′ are curved corresponding to the corner portion C of the coil 51. Further, since the gap 60 is formed only on the outer peripheral surface 62 side in the corner portion C, the length of the insulating member 70b is shorter in the radial direction of the coil 51 than the insulating member 70a. For the same reason, the insulating member 70 b of the insulating assembly 75 ′ is inserted into the gap 60 between the flat wires 50 only from the outer peripheral surface 62 side of the coil 51. However, in the case of the insulating assembly 75 ′ in which the heat radiation fins 76 are attached to the inner peripheral surface of the coupling portion 74 and the insulating member 70 b is provided on the outer peripheral surface, the insulating member 70 b of the insulating assembly 75 ′. Can be inserted from the inner peripheral surface 61 side of the coil 51.

  Since the gap 60 in the corner portion C is smaller than the gap 60 in the straight portion L, it is preferable to make the height (thickness) of the insulating member 70b smaller than the height (thickness) of the insulating member 70a. In this case, a minute gap (see FIG. 4A) between the insulating member 70 a and the flat wire 50 in the straight portion L of the coil 51 is defined between the insulating member 70 a and the flat wire 50 in the corner portion C of the coil 51. Are approximately the same size as the small gaps between (see FIG. 4B). Therefore, after impregnating the varnish 80, the flat wire 50 can be held to the same extent in both the straight portion L and the corner portion C of the coil 51.

  FIG. 6 is a front view of the coil. As shown in FIG. 6, the insulating assemblies 75 and 75 ′ may be disposed at the plurality of corner portions C and the plurality of straight portions L of the coil 51. Further, the insulating assemblies 75 and 75 ′ adjacent to each other may be integrally formed. In that case, it is desirable to form the insulating member 70b so that the thickness of the insulating member 70b and the radial direction length of the insulating member 70b gradually decrease along the corner portion C.

  Referring to FIG. 7A again, the flow of magnetic flux is indicated by arrows A1 to A3 in FIG. 7A. When the electrical angle is π / 6, magnetic flux flows through the iron cores 41 and 42 and the outer peripheral iron core 20 between the iron core 41 and the iron core 42 as indicated by an arrow A1. Furthermore, as indicated by arrows A <b> 2 and A <b> 3, leakage magnetic flux flows in a direction from the inner peripheral surface of the coil 51 toward the outer peripheral surface. In other words, the leakage flux is linked to the coil 51 in a direction perpendicular to the length of the iron core 41 in the radial direction.

  Further, referring to FIG. 7B, which is a partially enlarged view of FIG. 7A, the leakage magnetic flux A3 from the gap 101 links the coils 51 and 52 in the vicinity of the radially outer end of the gap 101. Similarly, the leakage flux from the gap is linked to the other coils 52 and 53, but in FIG. 7A, the density of the leakage flux of A3 is the highest. Similarly, leakage magnetic fluxes are linked to the coils 51 to 53 at other electrical angles. However, the description will be continued with reference to FIG. 7A for the purpose of avoiding redundant description.

  8A is an enlarged view of the iron core and coil shown in FIG. 7A, and FIG. 8B is a view similar to FIG. 8A in the prior art. In FIG. 8B, the coil 51 is formed from a plurality of copper plates 49, for example, a copper plate 49 having a thickness of 0.6 mm. Further, when the width of the plurality of copper plates 49 constituting the coil 51 is T1, and the length of the coil 51 in the stacking direction of the iron core 41 is L, the loop area of the eddy current generated by the interlinkage magnetic flux is expressed as T1 × L. Is relatively large. In this case, the copper loss due to the eddy current loss increases, and as a result, the temperature of the coil 51 also increases.

  As shown in FIG. 8A, the coil 51 is formed by edgewise bending a rectangular wire 50, for example, an enameled coated rectangular wire or a paper winding. The coil 51 in this case may be the coil described with reference to FIG. 4A. The same applies to the other coils 52 and 53. And as FIG. 8A shows, the coil 51 is arrange | positioned so that the adjacent surface 50a of the mutually adjacent rectangular wire 50 may become parallel to arrow A2. In other words, the adjacent surface 50 a of the flat wire 50 is perpendicular to the radial direction of the reactor 6. When the thickness of one rectangular wire 50 is T0, the loop area in this case is represented by T0 × L.

  As can be seen from FIGS. 8A and 8B, the thickness T0 of one rectangular wire 50 is sufficiently smaller than the width T1 of the coil 51 and the corresponding dimension of the copper plate 49. As a result, the loop area of the eddy current generated by the interlinkage magnetic flux is similarly reduced. In one embodiment, the flat wire 50 has a thickness T0 of 3 mm, and the coil 51 has a width T1 of 30 mm. In this case, the loop area can be reduced to 1/10. Therefore, it will be understood that an increase in copper loss due to eddy current loss can be suppressed, and as a result, an increase in the temperature of the coil 51 can be suppressed. Naturally, by further reducing the thickness T0 of the flat wire 50, it is possible to further suppress an increase in copper loss and a temperature increase in the coil 51.

  FIG. 9 is an enlarged perspective view of a coil in the third embodiment. In FIG. 9, a coil 51 (para-winding) is created by overlapping a plurality of, for example, three rectangular wires 50, and edge-wise bending a set of the overlapping rectangular wires 50. In this case, since the thickness of the flat wire is approximately one third, the loop area of the eddy current is further reduced, so that an increase in copper loss and a temperature rise in the coil 51 can be further suppressed. Moreover, the coil 51 made into the para coil | winding which consists of the some rectangular wire 50 can suppress the increase in the loss by a skin effect also with respect to a high frequency current. Further, instead of the flat wire 50, a coil may be similarly formed from a plurality of litz wires, and in this case, it will be understood that the same effect can be obtained.

  Furthermore, FIG. 10 is a cross-sectional view of the reactor in the fourth embodiment. The core body 5 shown in FIG. 10 includes a substantially octagonal outer peripheral core 20 and four iron core coils 31 to 34, which are disposed inward of the outer peripheral core 20 and are similar to those described above. . These iron core coils 31 to 34 are arranged at equal intervals in the circumferential direction of the core body 5. Moreover, it is preferable that the number of iron cores is an even number equal to or greater than 4, whereby the reactor including the core body 5 can be used as a single-phase reactor.

  As can be seen from the drawings, the outer peripheral core 20 is composed of four outer peripheral core portions 24 to 27 divided in the circumferential direction. Each of the iron core coils 31 to 34 includes iron cores 41 to 44 extending in the radial direction and coils 51 to 54 wound around the iron core. And each radial direction outer side edge part of the iron cores 41-44 is integrally formed with each of the outer peripheral part iron core parts 21-24. In addition, the number of the iron cores 41-44 and the number of the outer peripheral part iron core parts 24-27 may not necessarily correspond. The same applies to the core body 5 shown in FIG.

  Further, the radially inner ends of the iron cores 41 to 44 are located in the vicinity of the center of the outer peripheral iron core 20. In FIG. 4, the inner ends in the radial direction of the iron cores 41 to 44 converge toward the center of the outer peripheral iron core 20, and the tip angle is about 90 degrees. And the radial direction inner side edge part of the iron cores 41-44 is mutually spaced apart via the gaps 101-104 which can be connected magnetically.

  Coils 51 to 54 shown in FIG. 10 are formed by edgewise bending a rectangular wire 50, for example, an enamel-coated rectangular wire or a paper winding. Further, the coils 51 to 54 in this case may be the coils described with reference to FIG. 4A. Therefore, it will be apparent that the same effect as described above can be obtained also in this case.

Aspect of the Present Disclosure According to the first aspect, in the coil (51) formed by winding the enamel-coated flat wire (50), the flat wire has at least a partial gap (60) in the circumferential direction of the coil. Coils are provided that are spaced from each other and in which insulating members (70, 70a, 70b) are inserted in the at least partial gaps.
According to a second aspect, in the first aspect, an insulating assembly (75, 75 ′) including a coupling portion to which the insulating member is coupled is further provided.
According to a third aspect, in the second aspect, the insulation assembly further includes heat dissipating fins (76).
According to the fourth aspect, in the second or third aspect, the coupling part is formed with a through hole (77) through which the refrigerant passes.
According to a fifth aspect, in any of the first to fourth aspects, the coil is impregnated with a varnish (80).
According to a sixth aspect, in any one of the first to fifth aspects, the coil is formed by edgewise bending.
According to the seventh aspect, in any one of the first to sixth aspects, in the method of forming the coil (51), the rectangular wire with enamel coating (50) is wound, so that the rectangular wire becomes the coil. A coil forming method is provided in which at least a partial gap (60) is provided between each other in the circumferential direction so that the insulating members (70, 70a, 70b) are inserted into the at least partial gap. .
According to an eighth aspect, in any one of the first to seventh aspects, the method further includes impregnating the coil with a varnish.
According to the ninth aspect, the outer peripheral iron core (20) and at least three iron core coils (31 to 34) arranged on the inner side of the outer peripheral iron core are provided, and each of the at least three iron core coils. Is composed of an iron core (41 to 44) and a coil (51 to 54) wound around the iron core, and one of the at least three iron cores and another adjacent to the one iron core. A magnetically connectable gap (101 to 104) is formed between the iron core and the reactor (6), in which the coil is formed by winding a flat wire (50). .
According to a tenth aspect, in the ninth aspect, the flat wire is a flat wire with an enamel coating, and the flat wire is disposed mutually with at least a partial gap (60) in the circumferential direction of the coil. And an insulating member (70, 70a, 70b) is inserted into the at least partial gap. According to the eleventh aspect, in the ninth or tenth aspect, the flat angles of the coils adjacent to each other. Adjacent surfaces (50a) between the lines are perpendicular to the radial direction of the reactor.
According to a twelfth aspect, in any of the ninth to eleventh aspects, the coil is formed by edgewise bending.
According to a thirteenth aspect, in the twelfth aspect, the coil includes a plurality of rectangular wires superimposed on each other.
According to the fourteenth aspect, in any of the ninth to thirteenth aspects, the number of the at least three iron core coils is a multiple of three.
According to the fifteenth aspect, in any of the ninth to thirteenth aspects, the number of the at least three iron core coils is an even number of 4 or more.

Effect of Embodiment In the first and seventh embodiments, an insulating member is inserted into at least a partial gap of the coil. For this reason, when impregnating a varnish, a varnish stays in a clearance gap and a coil can be formed more firmly. Furthermore, since it is not necessary to press work, it is possible to prevent the coating from deteriorating or peeling off.
In the second aspect, the insulating member can be easily inserted into the gap of the coil.
In the third aspect, the heat dissipation action of the coil can be enhanced.
In the fourth aspect, the heat dissipation action of the coil can be enhanced.
In the fifth and eighth embodiments, the coil can be formed more firmly.
In the sixth aspect, the flat wire can be easily bent.
In the ninth aspect, an increase in copper loss and a rise in coil temperature can be suppressed.
In the tenth aspect, the same effect as in the first aspect can be obtained.
In the eleventh aspect, since the loop area of the eddy current can be reduced, an increase in the copper loss due to the eddy current loss can be suppressed, and as a result, the increase in the coil temperature can be further suppressed.
In the twelfth aspect, the flat wire can be easily bent.
In the thirteenth aspect, an increase in copper loss and a rise in coil temperature can be further suppressed. Further, an increase in loss due to the skin effect can be suppressed even for a high-frequency current.
In the fourteenth aspect, the reactor can be used as a three-phase reactor.
In the fifteenth aspect, the reactor can be used as a single-phase reactor.
While the first embodiment has been described using exemplary embodiments, those skilled in the art will recognize the above-described changes and various other changes, omissions, without departing from the scope of the first embodiment. It will be appreciated that additions can be made.

5 Core body 6 Reactor 20 Outer peripheral core 24 to 27 Outer peripheral core portion 31 to 34 Iron core coil 41 to 44 Iron core 50 Wire material 50a Adjacent surface 51 to 54 Coil 60 Clearance 60a, 60b Minute clearance 61 Inner peripheral surface 62 Outer peripheral surface 70, 70a, 70b Insulating member 74 Coupling part 75, 75 ′ Insulating assembly 76 Radiation fin 77 Through hole 80 Varnish 101-104 Gap

Claims (15)

In a coil made by winding a flat wire with enamel coating,
The rectangular wires are arranged with each other with at least a partial gap in the circumferential direction of the coil,
A coil in which an insulating member is inserted in the at least partial gap.   The coil according to claim 1, further comprising an insulating assembly including a coupling portion to which the insulating member is coupled.   The coil according to claim 2, wherein the insulating assembly further includes a radiation fin.   The coil according to claim 2 or 3, wherein a through hole through which the coolant passes is formed in the coupling portion.   The coil according to any one of claims 1 to 4, wherein the coil is impregnated with varnish.   The coil according to claim 1, wherein the coil is formed by edgewise bending. In the method of forming the coil,
Winding a rectangular wire with an enamel coating, so that the rectangular wire is arranged with a gap at least partially in the circumferential direction of the coil;
A method for forming a coil, wherein an insulating member is inserted into the at least partial gap.   Furthermore, the formation method of the coil of Claim 7 including impregnating the said coil with a varnish. The outer core,
Comprising at least three iron core coils arranged inside the outer peripheral iron core,
Each of the at least three iron core coils is composed of an iron core and a coil wound around the iron core,
A magnetically connectable gap is formed between one of the at least three iron cores and another iron core adjacent to the one iron core,
further,
The coil is a reactor formed by winding a rectangular wire. The rectangular wire is a flat wire with an enamel coating,
The rectangular wires are arranged with each other with at least a partial gap in the circumferential direction of the coil,
The reactor according to claim 9, wherein an insulating member is inserted into the at least partial gap.   The reactor according to claim 9 or 10, wherein an adjacent surface between the rectangular wires adjacent to each other of the coil is perpendicular to a radial direction of the reactor.   The reactor according to any one of claims 9 to 11, wherein the coil is formed by edgewise bending.   The reactor according to claim 12, wherein the coil includes a plurality of rectangular wires superimposed on each other.   The reactor according to any one of claims 9 to 13, wherein the number of the at least three iron core coils is a multiple of three.   The reactor according to any one of claims 9 to 13, wherein the number of the at least three iron core coils is an even number of 4 or more.