JP7470668B2 - Reactor electrical steel sheets - Google Patents

Description

The present disclosure relates to an electrical steel sheet for a reactor.

Reactors are widely used as electrical components for generating reactance. A reactor has a core formed by laminating multiple electromagnetic steel sheets, and a coil made of wire wound around this core.

Conventionally, cores have generally been manufactured by punching out parts having a specific shape. After stacking multiple such parts, they are welded together to form a single core (for example, see Patent Document 1 below or Patent Document 2 below).

JP 2013-93921 A Chinese Utility Model No. 206194495

However, with conventional core configurations, waste is easily generated when punching out the magnetic steel sheets, and there is a need to improve yield.

The present disclosure has been made to solve the above-mentioned problems, and has an object to provide an electrical steel sheet for a reactor that can improve the yield.

The electrical steel sheet for a reactor according to the present disclosure comprises two outer parts having a plate-shaped first portion extending in a first direction and at least three plate-shaped second portions formed integrally with the first portion , protruding to one side in a second direction perpendicular to the first direction and extending in the same plane as the first portion, and a central part having a plate-shaped third portion extending in the first direction and connecting ends of the at least three second portions, wherein the second portion located furthest to one side in the first direction among the at least three second portions is formed so that its dimension in the second direction is shorter by a predetermined length than the other second portions, and the central part further has a pair of protruding portions each protruding by the predetermined length from both ends of the third portion in directions away from each other in the second direction.

According to the present disclosure, it is possible to provide an electrical steel sheet for a reactor that can improve the yield.

1 is a cross-sectional view showing a configuration of a reactor according to a first embodiment of the present disclosure. FIG. 2 is an explanatory diagram showing a shape when punching out an electromagnetic steel sheet for a reactor according to the first embodiment of the present disclosure. FIG. 4 is a cross-sectional view showing a configuration of a reactor according to a second embodiment of the present disclosure. FIG. 11 is an explanatory diagram showing a shape when punching out an electromagnetic steel sheet for a reactor according to a second embodiment of the present disclosure. FIG. 4 is a cross-sectional view showing a configuration of a reactor according to a third embodiment of the present disclosure. FIG. 11 is an explanatory diagram showing a shape when punching out an electromagnetic steel sheet for a reactor according to a third embodiment of the present disclosure. FIG. 11 is an explanatory view showing the shape when another component is punched out from the electromagnetic steel sheet for a reactor according to the third embodiment of the present disclosure. FIG. 13 is an explanatory diagram showing a shape when punching out an electromagnetic steel sheet for a reactor according to a third embodiment of the present disclosure, and is a diagram showing a modified example. FIG. 13 is an explanatory diagram showing a shape when punching out an electrical steel sheet for a reactor according to a third embodiment of the present disclosure, and is a diagram showing a further modified example.

First Embodiment
(Reactor configuration)
Hereinafter, a reactor 100 and an electromagnetic steel sheet 90 for a reactor according to a first embodiment of the present disclosure will be described with reference to FIGS. 1 and 2. FIG.

The reactor 100 is a component used to generate reactance in an electric circuit. As shown in FIG. 1, the reactor 100 includes a core 1 and two coils (a first coil 51 and a second coil 52).

(Core Configuration)
The core 1 is formed by laminating in the thickness direction a plurality of plate-shaped reactor electromagnetic steel sheets 90. The reactor electromagnetic steel sheets 90 each have a central part 1a and a pair of outer parts 1b.

The central component 1a has a first portion 11 extending in a first direction D1 and a plurality (six) of second portions 12 extending in a second direction D2 perpendicular to the first direction D1. Three second portions 12 are provided on each of the two end edges of the first portion 11 in the second direction. The second portions 12 are formed integrally with the first portion 11 and are plate-like extending within the same plane. The distance between the second portions 12 in the first direction D1 is the same. Note that "same" here refers to being substantially the same, and manufacturing errors and design tolerances are allowed. The same applies to the following explanation.

The four second portions 12 located on both sides in the first direction D1 are provided at both ends of the first portion 11 in the first direction D1. In other words, the first portion 11 does not protrude on either side in the first direction D1.

Of the six second parts 12, a pair of second parts 12 located in the center in the first direction D1 may have smaller dimensions in the second direction D2 than the remaining second parts 12. This is to form an air gap between them and the outer part 1b, which will be described later.

The outer part 1b connects the three second parts 12 in the central part 1a in the first direction D1. In other words, the outer part 1b extends in the first direction across the three second parts 12.

(Coil configuration)
The first coil 51 and the second coil 52 are each formed by winding a wire several times around the second portion 12 in the center in the first direction D1. That is, the reactor 100 has two independent coils. The wire may be wound in any of various ways that have been proposed so far.

To form the reactor 100, the central part 1a and the outer part 1b, which have been punched into the above-mentioned shapes, are stacked in the thickness direction in multiple layers, and then wire is wound around them to form the first coil 51 and the second coil 52. The stack of the central part 1a and the stack of the outer part 1b are then welded together to complete the reactor 100.

(Regarding punching shapes of electromagnetic steel sheets for reactors)
Next, the punched shape of the reactor electromagnetic steel sheet 90 will be described with reference to FIG. 2. The die (blade) used for punching the reactor electromagnetic steel sheet 90 has the shape shown in FIG. 2. That is, the second portions 12 of the central parts 1a are arranged facing each other, and the outer part 1b is arranged in the area between the second portions 12. Therefore, the dimension of the outer part 1b in the first direction D1 is twice the dimension of the second portion 12 in the second direction D2. That is, in a pair of central parts 1a arranged facing each other, the outer part 1b is arranged so as to fill the area of the area surrounded by the four second portions 12. In addition, as a result, the dimension (width dimension) of the outer part 1b in the second direction D2 is the same as the separation distance between the second portions 12 in the first direction D1.

(Action and effect)

Conventionally, when manufacturing the core 1, it was common to obtain parts having a predetermined shape by punching. A number of such parts were then stacked and welded together to form a single core. However, with the conventional core structure, waste was easily generated when punching the electromagnetic steel sheet, and there was a demand for improving the yield.

The above configuration can improve the yield of the plate material used to form the central component 1a and the outer component 1b by punching. In other words, the amount of wasted material can be reduced. Specifically, a pair of central components 1a can be combined with their second portions 12 facing each other, and punching can be performed with the outer component 1b positioned between the adjacent second portions 12. This can improve the yield.

In addition, according to the above configuration, the dimension of the outer part 1b in the second direction D2 is twice the protruding length of the second parts 12, so that the area formed between the second parts 12 can be used as the outer part 1b without waste.

Furthermore, according to the above configuration, the dimension of the outer part 1b in the first direction D1 is the same as the distance between the second parts 12, so that the area formed between the second parts 12 can be used as the outer part 1b with less waste. This makes it possible to greatly improve the yield when obtaining the reactor electromagnetic steel sheet 90 from a single steel sheet.

In addition to the above-mentioned effects, in the reactor 100, the axial direction of the two coils is the same, so that the vibration caused by excitation can be cancelled between these two coils. In particular, when the reactor 100 is operated in an interleaved manner, the current phases are different between the two coils. The above-mentioned vibration reduction effect can be obtained by canceling out the fundamental components of the current, which are the fundamental components and the carrier components. Generally, reactors made of electromagnetic steel sheets are fixed to the housing on the long side (i.e., the outer part 1b side) with screws or the like, but in the reactor 100 according to this embodiment, vibration occurs parallel to the long side, so that it is possible to reduce the vibration transmitted to the housing.

Furthermore, in reactor 100, each coil is housed inside core 1. In other words, it is possible to increase the size of core 1 compared to when coils of the same size are arranged so that they are exposed to the outside of core 1. As a result, the length of the magnetic path is expanded overall, and the coupling coefficient can be kept small. This can further improve the performance of reactor 100.

The above describes the first embodiment of the present disclosure. Note that various changes and modifications can be made to the above configuration without departing from the gist of the present disclosure. For example, in the above first embodiment, an example was described in which three second portions 12 are formed on each side of the central component 1a, thereby forming a total of two coils. However, the number of coils can be changed to four or more depending on the design and specifications.

Second Embodiment
Next, a second embodiment of the present disclosure will be described with reference to Fig. 3 and Fig. 4. Note that the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted. As shown in Fig. 3, a reactor 200 according to this embodiment includes a core 2 and two coils (a first coil 51 and a second coil 52).

(Core configuration)
As in the first embodiment, the core 2 is formed by laminating a plurality of plate-shaped reactor electromagnetic steel sheets 90b in the thickness direction. The reactor electromagnetic steel sheets 90b have a central part 2a and a pair of outer parts 2b.

The central component 2a has a first portion 21 extending in a first direction D1 and a plurality (six) of second portions 22 extending in a second direction D2 perpendicular to the first direction D1. Three second portions 22 are provided on each of the two end edges of the first portion 21 in the second direction D2. The distances between the second portions 22 in the first direction D1 are the same.

The four second portions 22 located on both sides in the first direction D1 are provided at both ends in the first direction D1 of the first portion 21. In other words, the first portion 21 does not protrude on both sides in the first direction D1.

The outer component 2b has three third portions 23 extending in the second direction D2 to face the three second portions 22, and a fourth portion 24 connecting the three third portions 23 to each other in the first direction D1. This makes the outer component 2b E-shaped as a whole. Such stacks of outer components 2b are attached one by one to both sides of the stack of the central component 2a in the second direction D2.

The protruding length of the second portion 22 relative to the first portion 21 and the protruding length of the third portion 23 relative to the fourth portion 24 are the same. In addition, the spacing between the second portions 22 and the spacing between the third portions 23 are the same. Furthermore, the spacing between the second portions 22 is the same among the three second portions 22. Similarly, the spacing between the third portions 23 is the same among the three third portions 23.

Of the six second parts 22, a pair of second parts 22 located in the center in the first direction D1 may have a smaller dimension in the second direction D2 than the remaining second parts 22. Similarly, of the six third parts 23, a pair of third parts 23 located in the center in the first direction D1 may have a smaller dimension in the second direction D2 than the remaining third parts 23. This is to form an air gap between the central part 2a and the outer part 2b.

(Coil configuration)
The first coil 51 and the second coil 52 are each formed by winding a wire several times around the second portion 22 in the center in the first direction D1. That is, the reactor 200 has two independent coils. The wire may be wound in any of various ways that have been proposed so far.

(Regarding punching shapes of electromagnetic steel sheets for reactors)
Next, the punched shape of the reactor electromagnetic steel sheet 90b will be described with reference to Fig. 4. The die (blade) used to punch the reactor electromagnetic steel sheet 90b has the shape shown in Fig. 4. That is, the outermost third portion 23 of the three third portions 23 of the outer component 2b is fitted into the gap between the second portions 22 of the central component 2a. By continuously repeating such an arrangement, the punching process is performed.

(Action and Effect)
According to the above configuration, by fitting the outermost third portion 23 of the outer component 2b into the gap between the second portions 22 of the central component 2a, it is possible to reduce the possibility of waste being generated during the punching process.

In addition, with the above configuration, the dimension of the third portion 23 in the first direction D1 is the same as the distance between the second portions 22, so that the area between the second portions 22 of the central component 2a can be used without waste.

In addition to the above-mentioned effects, in the reactor 200, the axial direction of the two coils is the same, so that the vibration caused by excitation can be cancelled between these two coils. In particular, when the reactor 200 is operated in an interleaved manner, the current phases are different between the two coils. The above-mentioned vibration reduction effect can be obtained by canceling out the fundamental components of the current, which are the fundamental components and the carrier components. Generally, a reactor made of electromagnetic steel sheet has its long side (i.e., the outer part 2b side) fixed to the housing with screws or the like, but in the reactor 200 according to this embodiment, vibration occurs parallel to the long side, so that it is possible to reduce the vibration transmitted to the housing.

The above describes the second embodiment of the present disclosure. Note that various changes and modifications can be made to the above configuration without departing from the gist of the present disclosure. For example, in the above second embodiment, an example was described in which three second portions 22 are formed on each side of the central component 2a, thereby forming a total of two coils. However, the number of coils can be changed to four or more depending on the design and specifications.

Third Embodiment
Next, a third embodiment of the present disclosure will be described with reference to Fig. 5 to Fig. 7. Note that the same components as those in the above-described embodiments are denoted by the same reference numerals, and detailed description thereof will be omitted. As shown in Fig. 5, a reactor 300 according to this embodiment includes a core 3 and two coils (a first coil 51 and a second coil 52).

(Core Configuration)
As in the above-described embodiments, the core 3 is formed by laminating a plurality of plate-shaped reactor electromagnetic steel sheets 90c in the thickness direction. The reactor electromagnetic steel sheet 90c has a pair of outer parts 3a and a central part 3b.

The outer part 3a has a first portion 31 extending in the first direction D1 and three second portions 32 extending from the long side of the first portion 31 in the second direction D2. The distance between the second portions 32 in the first direction D1 is the same. Of the three second portions 32, one second portion 32 (small second portion 32s) located on one side of the first direction D1 has a dimension in the second direction D2 smaller than the remaining two second portions 32 by a predetermined length (unit length in the case of FIG. 5). The unit length here refers to the width of the first portion 31 in the second direction D2. Of the remaining two second portions 32, only the second portion 32 located in the center of the first direction D1 can be formed slightly shorter than the remaining one second portion 32 in order to form an air gap. In other words, it is possible to make the dimensions in the second direction different between the three second portions 32.

A pair of outer parts 3a having this shape are provided in a position that is point symmetrical with respect to the first direction D1.

The central part 3b has a third part 33 that extends in the first direction D1 and connects the ends of the three second parts 32 together, and a pair of protruding parts 34 that protrude from both ends of the third part 33 in the first direction D1 by a unit length (described above) in directions away from each other in the second direction D2.

(Coil configuration)
The first coil 51 and the second coil 52 are each formed by winding a wire several times around the second portion 32 in the center in the first direction D1. That is, the reactor 300 has two independent coils. The wire can be wound in any of various ways that have been proposed so far.

(Regarding punching shapes of electromagnetic steel sheets for reactors)
Next, the punched shape of the reactor electromagnetic steel sheet 90c will be described with reference to Figs. 6 and 7. The die (blade) used for punching the reactor electromagnetic steel sheet 90c has the shape shown in Figs. 6 and 7. That is, as shown in Fig. 6, a set of two outer parts 3a connected together in the second direction D2 is arranged so that the outermost second parts 32 are engaged with each other. At this time, the length of the outer side of the outermost second part 32 of one outer part 3a in the second direction D2 and the protruding length of the central second part 32 of the other outer part 3a in the second direction D2 are the same, so that the left and right ends of the set are aligned. In the set of two outer parts 3a, the central second part 32 of one outer part 3a is connected so as to be continuous with the outermost second part 32 of the other outer part 3a. By continuously repeating such an arrangement, the outer parts 3a are punched. Afterwards, or simultaneously with the punching process, the two connected outer parts 3a are cut along the dotted lines in FIG.

As shown in FIG. 7, the central part 3b is formed into a set with the protruding parts 34 facing each other, and is punched out so that multiple sets are continuously laid out on a plane.

According to the above configuration, by arranging the second parts 32 of the outer parts 3a in an engaged state, the possibility of waste occurring during the punching process can be further reduced. In addition, when punching the central part 3b, the plane can be filled with the specified shape without any gaps, improving the yield.

In addition to the above-mentioned effects, in the reactor 300, the axial direction of the two coils is the same, so that the vibration caused by excitation can be cancelled between these two coils. In particular, when the reactor 300 is operated in an interleaved manner, the current phases are different between the two coils. The above-mentioned vibration reduction effect can be obtained by canceling out the fundamental components of the current, which are the fundamental components and the carrier components. Generally, reactors made of electromagnetic steel sheets are fixed to the housing on the long side (i.e., the outer component 3a side) with screws or the like, but in the reactor 300 according to this embodiment, vibration occurs parallel to the long side, so that it is possible to reduce the vibration transmitted to the housing.

The above describes the third embodiment of the present disclosure. Note that various changes and modifications can be made to the above configuration without departing from the gist of the present disclosure. For example, in the above third embodiment, an example was described in which three second portions 32 are formed on each side of the outer component 3a, forming a total of two coils. However, the number of coils can be changed to four or more depending on the design and specifications.

Furthermore, as a modified example, as shown in FIG. 8, it is also possible to eliminate one of the second portions 32. That is, in this case, the dimension of one second portion 32 in the second direction D2 is 0. By forming the outer part 3a in this shape, it becomes possible to adopt a die (blade) arrangement as shown in FIG. 8 during punching (arranging the second portions 32 with a length of 0 facing each other), which makes it possible to further improve the yield.

Also, as shown in FIG. 9, it is possible to make the dimension of one second portion 32 in the second direction D2 even shorter than in the third embodiment. Specifically, in the third embodiment, one second portion 32 is formed shorter by one unit length. On the other hand, in the example of FIG. 9, one second portion 32 is formed shorter by twice this unit length as a predetermined length. In this case, as shown in FIG. 9, the arrangement of the dies (blade) becomes even more efficient, and the yield can be further improved.

<Additional Notes>
The reactor-use electromagnetic steel sheet 90 and the reactor 100 described in each embodiment can be understood, for example, as follows.

(1) The reactor electromagnetic steel sheet 90 according to the first embodiment includes a central part 1a having a plate-like first portion 11 extending in a first direction D1, and at least six plate-like second portions 12 that are integral with the first portion 11 and are provided on both sides of a second direction D2 perpendicular to the first direction D1, protruding from the first portion 11 and extending in the same plane as the first portion 11, and an outer part 1b having an area capable of filling the gap between the adjacent second portions 12 and extending in the same plane as the first portion 11 when a pair of the central parts 1a are combined so that the at least three second portions 12 face each other.

The above configuration can improve the yield of the plate material used to form the central component 1a and the outer component 1b by punching. In other words, the amount of wasted material can be reduced. Specifically, punching can be performed with the pair of central components 1a combined and the outer component 1b positioned between the adjacent second portions 12. This can improve the yield.

(2) In the reactor electromagnetic steel sheet 90 according to the second aspect, the dimension of the outer part 1b in the second direction D2 is twice the protruding length of the second portion 12 in the second direction D2.

According to the above configuration, the dimension of the outer part 1b in the second direction D2 is twice the protruding length of the second parts 12, so that the area formed between the second parts 12 can be used as the outer part 1b without waste.

(3) In the third aspect of the reactor-use electromagnetic steel sheet 90, the dimension of the outer part 1b in the first direction D1 is the same as the distance between the second portions 12 in the first direction D1.

With the above configuration, the dimension of the outer part 1b in the first direction D1 is the same as the distance between the second parts 12, so that the area formed between the second parts 12 can be used as the outer part 1b with even less waste.

(4) The fourth embodiment of the electromagnetic steel sheet 90b for a reactor includes a central part 2a having a plate-shaped first part 21 extending in a first direction D1, at least six second parts 22 integrally formed with the first part 21, at least three on each side of a second direction D2 perpendicular to the first direction D1, protruding from the first part 21 and extending in the same plane as the first part 21, and two outer parts 2b having at least three third parts 23 extending in the second direction D2 and positioned in the same position as the at least three second parts 22 in the first direction D1, and a fourth part 24 connecting the at least three third parts 23 to the first direction D1.

According to the above configuration, the outermost third portion 23 of the outer component 2b is fitted into the gap between the second portions 22 of the central component 2a, thereby reducing the possibility of waste being generated during the punching process.

(5) In the fifth aspect of the reactor electrical steel sheet 90b, the dimension of the third portion 23 in the first direction D1 is the same as the distance between the second portions 22 adjacent to each other in the first direction D1.

With the above configuration, the dimension of the third portion 23 in the first direction D1 is the same as the distance between the second portions 22, so that the area between the second portions 22 of the central component 2a can be used without waste.

(6) The sixth aspect of the reactor electromagnetic steel sheet 90c includes two outer parts 3a each having a plate-shaped first part 31 extending in a first direction D1 and at least three plate-shaped second parts 32 that are integral with the first part 31 and protrude to one side in a second direction D2 perpendicular to the first direction D1 and extend in the same plane as the first part 31, and a central part 3b having a plate-shaped third part 33 extending in the first direction D1 and connecting the ends of the at least three second parts 32. The second part 32 located on the furthest side in the first direction D1 among the at least three second parts 32 is formed to have a dimension in the second direction D2 that is shorter by a predetermined length than the other second parts 32, and the central part 3b further has a pair of protruding parts 34 that protrude from both ends of the third part 33 by the predetermined length in the direction away from each other in the second direction D2.

According to the above configuration, by arranging the second parts 32 of the outer parts 3a in an engaged state, the possibility of waste occurring during the punching process can be further reduced. In addition, the yield can be improved when punching the central part 3b.

(7) In the seventh aspect of the reactor electromagnetic steel sheet 90c, the second portion 32 located on the furthest side in the first direction D1 has a dimension of 0 in the second direction D2, and the protruding portions 34 protrude from both ends of the third portion 33 in directions away from each other in the second direction D2 by the dimension in the second direction D2 of the second portion 32 located on the furthest side in the first direction D1.

According to the above configuration, by arranging the second portions 32, each having a length of 0, facing each other, it is possible to further reduce the possibility of waste occurring during punching.

(8) The reactor 100 according to the eighth aspect includes a core 1 having a reactor electromagnetic steel sheet 90 according to any one of the above aspects stacked in the thickness direction, and coils (first coil 51, second coil 52) each having a wire wound around at least the second portion 12.

The above configuration allows for the provision of a reactor 100 with reduced cost by improving material yield.

100, 200, 300 Reactor 90, 90b, 90c Reactor electromagnetic steel sheets 1, 2, 3 Core 1a Central part 1b Outer part 11 First portion 12 Second portion 2a Central part 2b Outer part 21 First portion 22 Second portion 23 Third portion 24 Fourth portion 3a Outer part 3b Central part 31 First portion 32 Second portion 32s Small second portion 33 Third portion 34 Protruding portion 51 First coil 52 Second coil D1 First direction D2 Second direction

Claims (2)

A plate-shaped first portion extending in a first direction;
At least three second portions formed integrally with the first portions, protruding toward one side in a second direction perpendicular to the first direction and forming a plate shape extending in the same plane as the first portions;
and two outer parts having
a central part having a plate shape extending in the first direction and a third part connecting ends of the at least three second parts;
Equipped with
Among the at least three second portions, the second portion located furthest to one side in the first direction is formed to have a dimension in the second direction shorter by a predetermined length than the other second portions,
The central component is an electromagnetic steel sheet for a reactor, further including a pair of protruding portions that protrude from both ends of the third portion in directions away from each other in the second direction by the predetermined length. the second portion located on the furthest side in the first direction has a dimension of 0 in the second direction,
2. The electrical steel sheet for a reactor according to claim 1, wherein the protruding portions protrude from both ends of the third portion in directions away from each other in the second direction by an amount equal to the dimension in the second direction of the second portion located on the other side in the first direction.

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