JP6655525B2 - Transformers, iron cores and amorphous metal parts - Google Patents

Description

  The present invention relates to a transformer.

  Patent Document 1 discloses an amorphous iron core transformer having a large iron core width. Patent Document 1 discloses that "in an amorphous core transformer containing an iron core coil assembly formed by assembling an amorphous core made of an amorphous magnetic ribbon and a coil into which the amorphous core is inserted, the amorphous core has a width of When a plurality of different types of amorphous magnetic ribbons are abutted and arranged side by side, the amorphous magnetic cores are formed by alternately stacking the amorphous magnetic ribbons arranged side by side so that the mating surfaces of the arranged and aligned amorphous magnetic ribbons are shifted. Amorphous core transformer. "(See claim 1).

JP 2013-98349 A

  The wound core used in the transformer opens a part of the laminated core material and inserts a winding coil into the opened part. Thereafter, the open portion of the core material is wrapped. An iron core using an amorphous magnetic ribbon (hereinafter simply referred to as an amorphous ribbon or an amorphous material) as an iron core material is an amorphous iron core. To increase the capacity of an amorphous transformer having an amorphous core, it is necessary to increase the core width.

  However, the amorphous ribbon has a width of about several tens mm to about 200 mm because it is difficult to produce a wide ribbon. Since the thickness and the size of the ribbon having a width wider than this range vary, it is difficult to manufacture an amorphous iron core having a width larger than the width of the amorphous ribbon.

  Patent Literature 1 describes a transformer having an amorphous iron core in which a plurality of types of amorphous magnetic ribbons having different widths are arranged in abutting relation to each other to increase an iron core width.

  However, in Patent Document 1, although the amorphous ribbons are arranged side by side, it is performed manually, and therefore, no consideration is given to making the gap smaller.

  An object of the present invention is to provide a transformer having an iron core in which a gap between the arranged amorphous ribbons is small.

  In order to solve the above problems, an amorphous transformer as an example of the present invention is a transformer having a wound core and a coil wound around the wound core, and the wound core is formed of a plate-shaped metal member. The aggregate is stacked, and the aggregate of the plate-shaped metal members has a first layer in which two or more adjacent metal members are arranged with a gap therebetween, and a second layer, and a first layer. The metal member of the second layer and the metal member of the second layer which are in contact with each other have a joint portion at a portion where they overlap.

  According to the present invention, a transformer having stable magnetic characteristics can be provided.

It is a perspective view which shows the iron core and winding coil comprised by three phases and three windings. FIG. 3 is a perspective view showing a configuration of an iron core in which a set of four amorphous thin strips according to the embodiment of the present invention are laminated. It is a top view showing composition of a set of four amorphous ribbons concerning an example of the present invention. It is sectional drawing which shows the structure of a set of four amorphous ribbons concerning the Example of this invention. It is sectional drawing which shows the structure of a set of four amorphous ribbons concerning the Example of this invention. It is a figure showing an amorphous ribbon concerning an example of the present invention. It is sectional drawing of the iron core which concerns on the Example of this invention. It is sectional drawing of the iron core which concerns on the Example of this invention. It is a figure showing an example of an iron core manufacturing device concerning an example of the present invention. It is sectional drawing of a set of amorphous ribbon concerning the Example of this invention.

  Hereinafter, embodiments will be described with reference to the drawings. In all the drawings, members having the same functions are denoted by the same reference numerals, and the repeated description thereof will be omitted.

  In the following embodiments, when necessary for the sake of convenience, the description will be made by dividing into a plurality of sections or embodiments, but unless otherwise specified, they are not unrelated to each other, and one is the other. Some or all of the modifications, details, supplementary explanations, and the like are provided.

Further, in the following examples, when referring to the number of elements and the like (including the number, numerical value, amount, range, etc.), unless otherwise specified and in principle the number is clearly limited to a specific number, etc. However, the number is not limited to the specific number, and may be more than or less than the specific number.
Similarly, in the following embodiments, when referring to the shape, positional relationship, and the like of the components, the shape and the like are substantially the same unless otherwise specified, and in cases where it is considered that it is obviously not in principle. And the like or similar. The same applies to the above numerical values and ranges.

An embodiment of the present invention will be described below with reference to FIG.
FIG. 1 is a perspective view showing a three-phase three-legged amorphous core constituted by three-phase three windings and a winding coil assembly 30.
The amorphous core and the winding coil assembly 30 include a winding coil 40a on the outer core 30a and the inner core 30b, a winding coil 40b on the inner core 30b and the inner core 30c, and a winding coil on the inner core 30c and the outer core 30a. 40c are each wound.

Example 1 will be described with reference to FIGS. 2 to 5.
FIG. 2 shows the inner core 30b. It is the figure which did not display winding coil 40a and winding coil 40b for convenience of detailed explanation. The cc ′ section and the dd ′ section will be described later with reference to FIGS. 4A and 4B. Although the inner core 30b will be described as an example, the following description can be applied to the outer core 30a and the inner core 30c.

  A wide amorphous ribbon 1 and a narrow amorphous ribbon 2 are arranged in the inner core 30b. The wide amorphous ribbon 1 means that the width is wider than the narrow amorphous ribbon 2. In addition, bonding points 21 are arranged at a plurality of locations on the amorphous ribbon. The corners c1, c2, c3, c4 of the inner core 30b are shown. The junctions 21 are arranged at predetermined intervals.

  In the present specification, the thing used for the iron core is simply referred to as an amorphous ribbon because a thin ribbon-shaped amorphous metal member is used.

  Between the corner portions c2 and c3 is a wrap portion where the amorphous ribbons 1 and 2 are wrapped. As the wrapping method, overlap, step wrap, or a combination thereof can be used.

  By not arranging the joining points 21 at the corners c1 to c4, the outer peripheral side is pulled more than the inner peripheral side, so that a deviation between the inner peripheral side and the outer peripheral side hardly occurs. Details will be described later.

  The relationship between the junction 21 and the amorphous ribbons 1 to 4 will be described with reference to FIGS. 3A to 3C. The inner core 30b has a set of four amorphous ribbons 10 laminated. FIG. 3A shows a state before lapping a set of four amorphous ribbons 10 as inner cores 30b.

  Amorphous ribbons 1 and 2 are arranged on the first layer which is the upper layer, and amorphous ribbons 3 and 4 are arranged on the second layer which is the lower layer of the first layer, respectively. ing. On the upper side of the first layer, a wide amorphous ribbon 1 which is opened in the horizontal direction, and on the lower side, an amorphous ribbon 2 having a small width are arranged side by side substantially in parallel. A narrow amorphous ribbon 4 is similarly arranged on the upper side of the second layer, and a wide amorphous ribbon 3 is arranged on the lower side. The side surfaces of the amorphous ribbons arranged side by side are called abutting surfaces.

  The gap 22a is a solid line between the abutting surfaces of the amorphous ribbon 1 having a large width of the first layer and the amorphous ribbon 2 having a small width, and the amorphous ribbon 3 having a large width and the amorphous ribbon having a small width of the second layer. A gap 22b is shown by a broken line between the abutting surfaces with the band 4. By providing the gaps 22a and 22b at a predetermined distance in this manner, overlapping of the amorphous ribbons can be prevented.

  FIG. 3B is a diagram illustrating a cross section taken along line a-a ′ illustrated in FIG. 3A. An amorphous ribbon 3 having a small width is shown in a first layer which is an upper layer, and an amorphous ribbon 4 having a small width is shown in a second layer which is a lower layer. On the far side (not shown), a wide amorphous thin strip 1 is arranged in the first layer, and a wide amorphous thin strip 3 is arranged in the second layer.

  FIG. 3C is a cross-sectional view taken along the line b-b 'of FIG. A wide amorphous ribbon 1 and a narrow amorphous ribbon 2 are arranged via a gap 22a from the first end 50a side shown on the right side of the first layer in the drawing.

  Also, the amorphous thin ribbons 4 having a small width are arranged from the first end 50a side of the second layer via the gaps 22b. The width of the wide amorphous ribbons 1 and 4 is Wl, and the width of the narrow amorphous ribbons 2 and 3 is Ws.

  The width of the gaps 22a and 22b can be reduced to a value smaller than Ws, that is, smaller than the width of the narrow amorphous ribbons 2 and 3. Since the amorphous ribbons 1 to 4 have undulation on the side surface, that is, the butt surface side, overlapping of the amorphous ribbons can be prevented by making the width of the gaps 22a and 22b larger than the undulation.

  The above undulation will be described with reference to FIG. In FIG. 3d, a wide amorphous ribbon 1a and a narrow amorphous ribbon 2a are arranged in the long side direction. An example in which the short side direction is partially omitted and the long side is enlarged is shown.

  The undulation varies from individual to individual, but is about a submillimeter (about 0.1 to 0.9 mm) in a high quality amorphous ribbon. It is difficult to perform matching by hand in consideration of such undulation.

  Therefore, the gaps 22a and 22b are set to 0.1 mm or more and 1 mm or less in consideration of the undulation so that the amorphous ribbons 1 and 2 are arranged side by side, so that the gap is made smaller than when they are manually joined. Can be. Consequently, the space factor of the iron core can be increased.

Here, the space factor is a ratio of the total thickness of the core members to the total thickness of the laminated cores. In other words, the smaller the air gap inside the core, the higher the space factor, and the better the magnetic properties of the core.
Further, when the gaps 22a and 22b have a width of 1 mm or more and 10 mm or less, automatic arrangement and the like can be performed on a production line, and productivity is increased. In addition, since the value is larger than the undulation, the overlap between the amorphous ribbons can be easily prevented. In addition, although it can be carried out even if it is 10 mm or more and 100 mm or less, it is better that the gap is as small as possible.

  When the sum of the amorphous ribbons 1 and 2 of the first layer and the gap 22a is equal to the sum of the amorphous ribbons 3 and 4 of the second layer and the gap 22b, the first end 50a and the second end With 50b, the end faces of the amorphous ribbon are aligned. That is, the relation of Wl + Ws of the first layer + the width of the gap 22a = Wl + Ws of the second layer + the width of the gap 22b. The end face of the iron core that comes into contact with the winding coils 40a and 40b becomes flat, which contributes to improving the space factor. By aligning the end surfaces, the side surface of the wound core 30b can be flattened.

  Here, the equal width of the amorphous ribbon means that the width of the amorphous ribbon in the product standard is the same. Since the side portions of the amorphous ribbon have errors such as distortion, the actual widths do not completely match.

  In the first layer, two types of amorphous ribbons having different widths are arranged in the order of the widths Wl and Ws from the first end 50a side, and in the order of the widths Ws and Ws from the first end 50a side of the second layer. They are staggered. By alternately arranging the first layer and the second layer, the positions of the gaps 22a and 22b on the butting surfaces are different between the upper and lower layers.

  A set of four amorphous ribbons 10 are welded by laser or electric resistance. A junction 21 is shown where a part of the overlapping portion of the first and second layers of the amorphous ribbon is welded. Since the size of the welded portion differs depending on the welding conditions, the joint 21 is also called a joint.

The joining at the joining point 21 may be formed as a joining line continuously in the bb ′ direction shown in FIG. 3A. That is, they may be joined so as to have a length in the long side direction. These joining methods are not particularly limited, and laser joining can be performed by a method of intermittent joining by pulse irradiation.

  When electric resistance bonding is used, a seam bonding method using a rotating electrode may be employed. The method of applying electric resistance does not need to be continuous, and may be intermittently applied and joined. Further, it is preferable that the number of joints is set to such a number that a set of four amorphous ribbons 10 can be fixed so as not to be separated by spot welding which is one of electric resistance welding.

  When the bonding is performed, the amorphous amorphous ribbon is crystallized. However, since the first layer and the second layer are metal-bonded, a stronger connection is obtained as compared to a mere contact between the amorphous ribbons. . The strength can be adjusted according to the bonding area.

  By reducing the area of the joint 21, the crystallization region generated by welding the amorphous ribbon can be reduced, and the flow of the magnetic circuit can be reduced and the function of increasing the loss can be reduced.

  The width of the cross section of the joining point 21 is preferably 1 mm or less. Assuming that the width of the narrow amorphous ribbons 2 and 4 is 100 mm and the width of the wide amorphous ribbons 1 and 3 is 200 mm, the total width of the wide amorphous ribbon (sum of the width of the amorphous ribbons) Is about 300 mm.

  Assuming that the joining width of one joining line is 1 mm, there are three joining points 21 so that the total is 3 mm. Since the total width of the junction 21 obstructing the flow of the magnetic circuit is 3 mm with respect to the entire width of the amorphous ribbon of 300 mm, the loss is about 1% as compared with the case where all the amorphous ribbons are made amorphous. Can be suppressed. The effect is small compared to other parameters.

  In this embodiment, the first and second layers of the amorphous ribbon are described as one layer. However, the first and second layers of the amorphous ribbons are bundled in the layer direction by 10 sheets. Can also. When the number of layers is increased in this way, the lapping work time of the iron core can be reduced. The number is not limited to ten and may be several other sheets.

  This can be implemented by providing at least two joining points 21 in a plane area between the corners c1 to c4 when assembled as the iron core 30b. By joining two points in the horizontal direction between the corner portion c1 and the corner portion c2, it is possible to make it difficult for the gap between the planar regions to be misaligned.

  The plane region refers to a portion where the amorphous ribbon becomes vertical or horizontal when assembled as an iron core. In addition, the corner portion refers to a region where the amorphous ribbon has a curvature more than a flat portion when assembled as an iron core. That is, a bent region of the amorphous ribbon of the iron core after assembly is a corner portion, and a planar region is a region that is not bent.

  Therefore, the joining points 21 are provided at different intervals in the longitudinal direction of the set of four amorphous ribbons 10. This means that the joining points 21 are arranged at different intervals in the radial direction when assembled as an iron core.

  The different intervals are different intervals in which the first interval, which is a wide interval between the junctions 21 such as the corners c1 and the second interval, which is the junction 21 between the corners c1 and c2, is narrow. In some cases, in the set of four amorphous thin ribbons 10 on the inner peripheral side of the iron core, the interval between the joining points 21 may be shorter at the corner portion c1 than in the planar region. This is because the area of the corner portion c1 is narrow because the inner peripheral side has a small curvature. In any case, the number of junctions 21 in the longitudinal direction of the amorphous ribbon is larger in the planar region.

  Here, the flow of the magnetic circuit when a set of four amorphous thin ribbons 10 are stacked and assembled as an iron core 30b is in the depth direction of FIG. 3C. In order not to hinder the flow of the magnetic circuit, the smaller the horizontal junction area of the junction 21 when projected on the b-b 'section, the better.

Therefore, as shown in FIG. 3A and FIG. 3C, it can be implemented if there are three joining points 21 of the set of four amorphous ribbons 10 in the short side direction of the amorphous ribbon.
That is, the overlapping portions of the amorphous ribbon 1 having a wide first layer and the amorphous ribbon 4 of the second layer are joined, and the amorphous ribbon 1 having a wide first layer and the amorphous ribbon having a wide second layer are joined. If the overlapping portions of the strips 3 are joined, and the overlapping portions of the amorphous ribbons 2 having a narrow first layer and the amorphous ribbons 3 having a wide second layer are joined, a set of four amorphous The ribbon 10 can be fixed without falling apart. That is, the relationship is such that the amorphous ribbons of the first layer and the amorphous ribbons of the second layer, which are alternately arranged, are alternately connected via the bonding portion 21.

  The number of the overlapping points 21 is not limited to one, but may be two or more in the short side direction of the amorphous ribbon.

  The thickness of the amorphous ribbon is one tenth or less of the thickness of a silicon steel plate as a general iron core material, and a typical thickness is 50 μm or less. When the core of the transformer is formed of an amorphous ribbon, if the thickness of the core is, for example, 100 mm, the number of laminated cores is 2,000 or more.

  As in the past, it is possible in principle to laminate approximately 2,000 widely arranged amorphous ribbons without joining the amorphous ribbons. However, in practice, the work of assembling the winding coil and the winding core are not necessary. Due to the lapping operation, the position of the amorphous ribbon is shifted. This may reduce the space factor of the iron core.

  At this time, it is necessary to correct the gap between the gaps 22a and 22b and the end portions by manual operation or the like. Such manual work is inefficient and increases production costs. Further, it is difficult to manually align the widths of the gaps 22a and 22b and the ends of each layer.

  On the other hand, according to the configuration of the embodiment of the present invention described above, a set of four amorphous thin ribbons 10 can be treated as one amorphous thin ribbon. Therefore, at the time of the lapping operation, the assembling operation of the iron core can be performed without considering the positional deviation of the gaps 22a and 22b.

  Next, the thickness of the junction 21 will be described. It is desirable that the thickness of the junction 21 be as close as possible to the sum of the thicknesses of the amorphous ribbons of the first layer and the second layer. By preventing the junction at the junction 21 from rising, the thickness of the set of four amorphous ribbons 10 becomes flat.

  As a result, it is possible to prevent the space factor from lowering when assembled as an iron core. The thickness of the joining point 21 can be joined without being thicker than the thickness of the amorphous ribbon depending on the welding conditions of laser or electric resistance welding. Even if the junction 21 has a thickness, the thickness can be reduced by arranging the positions of the junctions 21 differently for each set of four amorphous ribbons 10.

  In addition, since the joining point 21 is provided, when the coil is inserted into the butted amorphous ribbon, the butted surface can be fixed so as not to move before and after the lapping operation. That is, it is possible to suppress a change in the gap between the butted amorphous ribbons before and after the lapping operation.

  By providing the bonding points 21 on the above-described set of four amorphous ribbons 10, it is possible to prevent the positional deviation of the corner portions of the amorphous ribbons and the change in the width of the gaps 22a and 22b during lapping. The space factor is stable when assembled as an iron core. Further, by stabilizing the space factor of the iron core, it is possible to provide a transformer having stable magnetic characteristics. The magnetic characteristic is one of the characteristics of the iron core determined by the magnetic permeability and the space factor of the iron core material.

  Next, an example of the configuration of the corners c1 to c4 will be described. As shown in FIGS. 2 and 3a, this is an example in which the junction 21 is not provided at the corner.

  It is also possible to implement the case where there is a joint 21 at the corners c1 to c4. However, compared to the case where there is no joint, the strain increases around the joint 21 and undulation tends to occur in the vertical direction (layer direction). is there. If bending is performed while the upper and lower surfaces are joined, the upper and lower ribbons have different radii of curvature, so that the distance between the joining points is different between the upper and lower portions. That is, when the bonding points 21 are arranged at regular intervals, a tensile stress is generated in the amorphous ribbon of the first layer as compared with the amorphous ribbon of the second layer.

  Therefore, a force is applied to the joining point 21, and a strain is generated, which causes undulation in the vertical direction. When about 2,000 amorphous thin strips having the junctions 21 provided at the corners c1 to c4 are stacked, the undulation in the vertical (layer) direction is amplified, so that the corners c1 to c4 have a thickness and the space factor is reduced. Invite.

  When the joints 21 are not provided at the corners c1 to c4 in the configuration of the present embodiment, even if the corners are bent when assembled as an iron core, the difference in the radius of curvature of the upper and lower surfaces is shifted in the circumferential direction. As a result, no distortion occurs when the joint exists. Therefore, it is difficult for the space factor to decrease at the corners. As a result, the magnetic properties as an iron core can be improved as compared with a case where a joint is provided at a corner portion.

  Further, even when the angle between the end face between the corners c1 and c2 and the end face between the corners c2 and c3 of the amorphous ribbon is slightly different, the corner c2 can absorb the deviation.

  FIGS. 4A and 4B are views showing the state of the c-c 'section and the d-d' section of the iron core 30b of FIG. FIG. 4A is a cross-sectional view taken along a line c-c 'in a plane region of the wound core 30b. 4a, the upper side is the inner side, and the lower side is the outer side. This figure shows a part of an example in which thousands of sets of four amorphous ribbons 10 are stacked, and three junction points 21 (three lines) are formed in each set of four amorphous thin ribbons 10. ing.

  FIG. 4B is a cross-sectional view taken along a line d-d 'of the corner c1 of the wound core 30b. 4b, the upper side is the inner side, and the lower side is the outer side. Thousands of the amorphous thin ribbons 10 are stacked in groups of four, but the junction 21 is not formed on the inner peripheral side (upper side in FIG. 4B) of the corner portion c1.

  A joining point 21 is formed on the outer peripheral side (the lower side in FIG. 4B) of the iron core corner portion c1. Since the radius of curvature is small on the inner peripheral side of the corner c1, a set of four amorphous ribbons 10 without the junction 21 are arranged in the corner c1 in consideration of the effect of increased strain around the junction 21.

  Further, since the radius of curvature is large on the outer peripheral side of the corner portion c1, even if the corner portion c1 has the joint point 21, the distortion is small and the magnetic performance is hardly affected. In consideration of the workability of iron core assembly, a set of four amorphous ribbons 10 each having a joint 21 are arranged at the outer peripheral side corner portion c1. The same applies to the other corner portions c2 to c4.

  If the joining points 21 such as the corners c1 are arranged in a straight line or on a curve from the inner peripheral side to the outer peripheral side in accordance with the curvatures of the amorphous ribbons on the inner peripheral side and the outer peripheral side, the misalignment of the amorphous ribbons may occur. This is effective because it hardly occurs.

  In the present embodiment, a set of four amorphous ribbons 10 each having the junction 21 provided on the outer peripheral side of the corner portion c1 are arranged. However, the size of the radius of curvature of the corner portion, the workability of iron core assembly, and the like are taken into consideration. A set of four amorphous ribbons 10 having no junction 21 may be arranged on the outer peripheral side. That is, the plane area of the iron core 30b is reduced, and the area such as the corner portion c1 is increased.

  Although not shown, a joining point 21 may be provided on the inner peripheral side of the corner portion, and a set of four amorphous ribbons 10 in which the number of welding points is smaller than the number of points in the plane area may be arranged. That is, at the corner portion c1 of the amorphous ribbon on the inner peripheral side of the center of the iron core, the joining points 21 having a wider interval than the interval of the joining points 21 in the plane area are arranged.

  Since the inner peripheral side is hardly affected by the curvature, by providing the bonding points 21 at a pitch wider than the plane area in the corner portion c1, the positional deviation is less likely to occur. In other words, even when the joining points 21 are provided at the corners c1, the distortion of the corners c1 can be reduced by reducing the number of joining points.

  Alternatively, a set of four amorphous ribbons 10 in which the interval between the joining points between the planar region and the corner portion, that is, the interval between the joining points 21 is adjusted for each lamination may be arranged. That is, the interval between the joining points 21 is different between the inner peripheral side and the outer peripheral side amorphous ribbon.

  As another modified example, a set of four amorphous thin ribbons 10 in which the intervals between the joints 21 are formed at fixed points are arranged and laminated, and the periphery of the joint such as the corner c1 is intentionally pulled to correspond to the corner c1 or the like. Some of the joining points 21 may be peeled off to reduce the distortion when forming a bend, thereby forming a wound iron core. This means that the corner portion c1 has a crystallized portion where the first layer and the second layer are not joined. In this case, the welding process of the amorphous ribbon is simplified.

  Further, in the assembly process, the bonding state is such that the bonding point 21 of the corner portion c1 is peeled off when a strong stress is applied thereto. Is not peeled off, so that stress can be released even when the assembly is misaligned, which is effective.

  A method for manufacturing a set of four amorphous ribbons 10 will be described with reference to FIG. A state is shown in which the welding means 26 is arranged above the arranged first set of four amorphous ribbons 10 and the laser 27 is irradiated from the welding means 26. Further, a cutting means 28 for cutting a set of four amorphous ribbons 10 is shown.

  First, in order to manufacture a set of four amorphous ribbons 10, four amorphous ribbons cut to a predetermined length in the longitudinal direction are provided with gaps 22a and 22b in the first and second layers, respectively. Arrange them in a staggered manner. This arrangement may be performed manually, but since the same operation is repeatedly performed, it is preferable to efficiently arrange and arrange by a transfer robot or the like. Further, the width of the gaps 22a and 22b is preferably set to a size in consideration of the productivity described above.

  The linearity in the longitudinal direction of the amorphous ribbon is accompanied by a swell of about sub-millimeter. If the gap 22a is to be controlled at, for example, 50 μm or less, highly accurate control and monitoring are required. In some cases, the undulations may interfere with each other and the abutment surfaces may overlap with each other.

  Next, a portion where the amorphous ribbons of the first layer and the second layer overlap each other is joined by the joining device 26. The bonding device 26 is a laser bonding device as a representative example, and the amorphous thin ribbon 1 is irradiated with a laser 27. The joining device 26 may be movable in the vertical direction in the figure. Alternatively, when three amorphous ribbons 10 arranged in a set of three are transported, they can be appropriately joined together.

  A predetermined length of the bonded four-piece amorphous ribbons 10 is transported to a predetermined cutting position and cut by the cutting means 28. Thus, a set of four amorphous thin ribbons 10 is formed.

  The cutting means 28 can be cut by heat using laser, electric resistance welding, or the like. In the case of laser or electric resistance welding, the same device as the joining device 26 can be used, so that a separate cutting device does not need to be provided. The use of a cutting means such as a dicing saw or a band saw is effective because the crystallization region can be reduced.

  It is possible to increase the number of junctions in the short side direction around the cutting means 28 to facilitate cutting. That is, the number of junctions 21 in the short side direction of the plane region is three as shown in the figure, while the right side of the cutting means 28 is set to five points in the short side direction of the amorphous ribbon. is there.

  The above-described set of four amorphous ribbons 10 of the present invention is wrapped to form an iron core 30b. As an example of the method, overlapping is performed. In this case, since the crystallized portion is only the junction 21, the area where the non-crystallized portions contact each other is large, and the flow of the magnetic circuit is not hindered.

  When overlapping and overlapping, the thickness of a set of four amorphous ribbons 10 (thickness of two amorphous ribbons) increases, but if the overlapping portion of the lower layer is shifted to form a step-lapping structure, several thousand sheets are formed. Even if a set of four amorphous thin ribbons 10 is stacked, the thickness will only increase. Accordingly, the iron core 30b can be configured to have a size obtained by adding the thickness of the set of amorphous thin ribbons 10 to the thickness of the laminated amorphous thin ribbons, and downsizing of the iron core can be realized. In other words, when a step wrap structure is formed by using a set of 1000 amorphous thin ribbons 10 each, an iron core can be formed with a thickness of 2002 sheets.

  Although the above embodiment has been described using an amorphous ribbon as a representative example, the present invention can be implemented with a plate-shaped metal member such as a silicon steel plate or a grain-oriented electromagnetic steel plate. Further, as a concept including an amorphous ribbon and a silicon steel plate, a set of four plate-shaped metal members is an aggregate of plate-shaped metal members.

  Embodiment 2 will be described with reference to FIG. So far, an example has been described in which two types of amorphous ribbons having a width of Wl and Ws are combined in each layer (two in total). However, an amorphous ribbon having a large width depending on the number and arrangement method in each layer is described. It is a configuration example.

  As shown in (a), a cross-sectional view of a set of six amorphous ribbons 10a of an example in which two types of amorphous ribbons having widths Wl and Ws are arranged in total of six ribbons is shown. From the first end 50c of the first layer to the second end 50d, one amorphous ribbon 100 having a width Wl and two amorphous ribbons 200 having a width Ws are arranged. Also, two amorphous thin strips 400 having a width Ws and one amorphous thin strip 300 having a width Wl are arranged from the first end 50c to the second end 50d of the second layer.

  In addition, a part of the overlapping portion of the amorphous ribbon 100 having the width Wl of the first layer and the amorphous ribbon 400 having the width Ws of the second layer is partially joined at the junction 21. 400 does not fall apart. In other amorphous ribbons, a part of a portion overlapping with an amorphous ribbon of a different layer is joined.

  The example of (b) is a cross-sectional view of a set of six amorphous ribbons 10b arranged in a different order from that of (a). From the first end 50c to the second end 50d of the first layer, two amorphous ribbons 100 and one amorphous ribbon 200 are arranged, and the second layer has one amorphous ribbon 400. And two amorphous ribbons 300 are arranged in order.

  The example of (c) is a cross-sectional view of a set of eight amorphous ribbons 10c different from (a) and (b). From the first end 50c to the second end 50d of the first layer, two amorphous ribbons 100 and two amorphous ribbons 200 are arranged. The second layer has one amorphous ribbon 400. Sheet, one amorphous thin strip 300, one amorphous thin strip 400, and one amorphous thin strip 300.

  Each of the four amorphous thin strips 10 described in the first embodiment, the six amorphous thin strips 10a and 10b in FIG. 6, and the eight amorphous thin strips 10c in FIG. 5, 5, 7 points.

  That is, when the number of the amorphous ribbons is four, the number of the bonding points 21 is three, and when the number of the amorphous ribbons is six, the number of the bonding points is five. Is a relation of n-1 where n is the number of amorphous ribbons to be used. In other words, by joining the overlapping portions of the amorphous ribbons by one less than the number of sheets used, the iron core material can be formed as one wide amorphous ribbon.

  Next, (d) will be described. The difference from the other examples is that a third type of amorphous ribbon 500 having a width Wm is used. As in the other examples, the amorphous ribbon of the first layer and the amorphous ribbon of the second layer are arranged so as to have overlapping portions, and a part of the overlapping portions is joined. Thus, the width of the amorphous ribbon can be implemented not only in two types but also in three types. In addition, the arrangement is an example, and the arrangement may be performed in another order as in (a) and (b). Further, not only three kinds of widths but also four kinds or more can be similarly implemented, and an iron core material having an arbitrary width can be formed.

  As described above, in the examples (a) to (c), the first layer and the second layer are constituted by the same combination of the width and the number of the amorphous ribbons. Cheap. That is, even if the order of arrangement is different for each layer, the amorphous ribbon used is the same combination for each layer, and it is easy to align the end faces. By aligning the end faces, the space factor as an iron core is improved.

  Next, the example of (e) will be described. Until now, an example in which one set of amorphous ribbons is formed using amorphous ribbons of different widths in each layer has been described. However, an example in which amorphous ribbons of the same width are used in each layer will be described.

  Three amorphous ribbons 200 having a width Ws are arranged in order from the first end 50c of the first layer, and two amorphous ribbons 300 having a width Wl are arranged in order from the first end 50c of the second layer. I have. A part of these overlapping portions is joined at a joining point 21. The idea of the present invention can be implemented by a combination of amorphous ribbons having at least two widths.

  Further, an example (f) will be described as a modification. A cross section of a set of six amorphous ribbons 10f is shown. The amorphous ribbon used is the same as in the example of (e). The difference is that the first layer and the second layer are aligned on the first end 50c side, but are not aligned on the second end 50d side.

  In this case, when assembled as an iron core, the second end 50d side can be made thinner. This is effective when a spacer or a buffer member is sandwiched between the iron core and the coil. As described above, the present invention can be implemented even when the first end 50c and the second end 50d do not necessarily coincide or align.

  It is also possible to implement all the amorphous ribbons of each layer as amorphous ribbons having the same width. In this case, the first and second ends are not aligned because the first and second layers of amorphous ribbons are provided with overlapping portions. This is an effective embodiment in a case where both ends of the iron core are rounded or a stepped iron core having a step at the end is used.

  With these methods, a wide amorphous iron core can be manufactured. In addition, since the joint point 21 is provided, the misalignment of the amorphous ribbon is less likely to occur when assembling the iron core, so that variations in core performance can be reduced. Further, it is not necessary to manually adjust the gap between the abutting surfaces, so that the production efficiency can be improved.

  Further, the width of the thin ribbon formed and joined (a set of four amorphous thin ribbons 10) has a small effect because the thickness of the original amorphous thin ribbon is increased by the amount of overlap, thereby contributing to downsizing of the iron core.

  Furthermore, although the junction 21 of the set of four amorphous ribbons 10 is crystallized, it is bonded with a small cross-sectional area to the flow of the magnetic circuit, so that the influence of the crystallized junction can be suppressed. it can. As a result, the influence of magnetic loss as an iron core or a transformer can be reduced.

  The configuration of each of the above-described embodiments is applicable not only to the transformer and the iron core of the transformer, but also to a reactor (stationary induction device) having an iron core and a coil. Also in this case, it is possible to reduce the variation in the space factor of the manufactured reactor for each iron core, and it is possible to provide a reactor having stable core characteristics.

1, 3,... A wide amorphous ribbon, 2, 4,... A narrow amorphous ribbon, 10, 10a, a set of four amorphous ribbons, 21, 21a, a joining point, 30a, an outer iron core, 30b, 30c. ... Inner core, 40a, 40b, 40c ... Coil, 50 ... Cross section of wide iron core, c1, c2, c3, c4 ... Corner part

Claims (11)

A transformer having a wound core and a coil wound around the wound core,
The wound iron core is formed by stacking an aggregate of plate-shaped metal members,
The assembly of the plate-shaped metal members has a first layer and a second layer, two or more of which are arranged so that the metal members are adjacent to each other,
A joining portion at a portion where the metal member of the second layer in contact with the metal member of the first layer overlaps;
The metal member of the first layer and the metal member of the second layer are alternately connected via the joint,
The metal member of the first layer has a metal member having a width of 2 or more,
A plurality of the joints are provided in a radial direction of the wound core,
A transformer, wherein more joints are provided in a plane region than in a corner portion of the wound core. A transformer having a wound core and a coil wound around the wound core,
The wound iron core is formed by stacking an aggregate of plate-shaped metal members,
The assembly of the plate-shaped metal members has a first layer and a second layer, two or more of which are arranged so that the metal members are adjacent to each other,
A joining portion at a portion where the metal member of the second layer in contact with the metal member of the first layer overlaps;
The metal member of the first layer and the metal member of the second layer are alternately connected via the joint,
The metal member of the first layer has a metal member having a width of 2 or more,
The metal member is an amorphous ribbon ,
A plurality of the joints are provided in a radial direction of the wound core,
A transformer, wherein more joints are provided in a plane region than in a corner portion of the wound core. The transformer according to claim 1 or 2,
The number of the joining portions is one or less than the sum of the number of the metal members of the first layer and the number of the metal members of the second layer, and is provided in a short side direction of the metal member. Transformer. The transformer according to any one of claims 1 to 3,
The transformer according to claim 1, wherein the metal member of the second layer includes a metal member having the same width as the metal member of the first layer. The transformer according to claim 4,
The width of the metal member on the first end side among the metal members of the first layer is the same as the width of the metal member on the second end side of the metal member of the second layer. Transformers characterized. The transformer according to any one of claims 1 to 5,
The transformer, wherein the joints are provided at different intervals in a longitudinal direction of the metal member.   The transformer according to claim 1, wherein:
  A transformer, wherein the first metal member and the second metal member are not joined at a corner of the wound core.   The transformer according to any one of claims 1 to 7,
  An end surface of a metal member disposed on a first end side of the first layer, which is a side surface of the core;
A transformer, wherein metal members arranged on the first end side of the second layer are arranged so that end faces thereof are aligned.   The transformer according to any one of claims 1 to 8,
  The said metal member is an amorphous ribbon, The transformer characterized by the above-mentioned.   The transformer according to claim 9,
  The said junction part is the said amorphous ribbon crystallized, The transformer characterized by the above-mentioned.   The transformer according to claim 9,
  A transformer, wherein the wrapping portion of the wound core is in contact with a portion different from the joining portion.

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