JPH05182840A - Amorphous wound core transformer and manufacture thereof - Google Patents

Abstract

PURPOSE:To inhibit the generation of fragments of an amorphous magnetic material and simplify the cover of the wound core. CONSTITUTION:Unit-laminates U1, U2,< formed by laminating a specified number of thin belts made of an amorphous magnetic material are laminated so as to manufacture a wound core C in joint sections of the unit laminates are located at one yoke. After windings W1 and W2 are mounted around the wound core C, resin P is applied to each end face of the unit laminates U1, U2,... when closing the joint J.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a transformer using an amorphous winding iron core and a method for manufacturing the transformer.

[0002]

2. Description of the Related Art Since an amorphous magnetic material is provided in the form of a ribbon, it is advantageous to take the form of a wound iron core when forming the iron core from the magnetic material. Since the ribbon of the amorphous magnetic material is extremely thin, it is difficult to adopt the method of assembling the wound core while inserting the ribbon into the window of the winding. Therefore, when manufacturing an amorphous winding iron core transformer, by laminating a number of unit laminates formed by stacking a predetermined number of thin strips of amorphous magnetic material, the joints at both ends of each unit laminate are After forming amorphous winding cores distributed in a stepwise manner on one yoke part, opening the joints of the winding cores and fitting the windings to the legs of the winding cores, both ends of each unit laminated body are formed. It is necessary to adopt a method of sequentially joining and closing the joint.

The amorphous winding iron core is annealed before the winding is fitted, but the amorphous magnetic material becomes brittle due to the annealing. Therefore, before fitting the winding, it is necessary to cover the portion excluding the yoke portion where the joint portion of the wound iron core is provided with a cover or the like to prevent the fragments of the magnetic material from leaking to the outside. Further, it is necessary to fit the winding wire to the winding core, close the joint portion of the iron core, and then cover the yoke portion of the iron core including the closed joint portion with a cover or the like.

[0004]

Since the cutting of the amorphous magnetic material is performed by a grindstone cutter, the cut surface thereof is particularly brittle due to heat. Therefore, when an impact is applied to the amorphous wound iron core, first, both ends of each unit laminate in which the cut surface of the magnetic material appears will be broken, and fragments of the magnetic material having conductivity will be generated. If this fragment leaks into the transformer case, dielectric breakdown may occur.Therefore, in order to ensure the reliability of the transformer over a long period of time, it is necessary to make the iron core coating strict. The cost of it was unavoidable. It is an object of the present invention to provide an amorphous winding iron core transformer and a method for manufacturing the same, in which fragments of the magnetic material are prevented from being generated from both ends of the unit laminate of the amorphous magnetic material.

[0005]

According to a first aspect of the present invention, a plurality of unit laminates formed by laminating a predetermined number of thin strips of an amorphous magnetic material are laminated to form a single joint at both ends of each unit laminate. The present invention relates to an amorphous winding core transformer provided with amorphous winding iron cores distributed in a stepwise manner on two yoke portions and windings fitted to the winding iron cores. Characterized by hardening. In the second invention of the present application, a plurality of unit laminates formed by laminating a predetermined number of thin strips of amorphous magnetic material are laminated, and the joints at both ends of each unit laminate are distributed stepwise on one yoke portion. By forming the amorphous wound iron core, opening the joint of the wound iron core and fitting the winding to the leg of the wound iron core, by sequentially joining both ends of each unit laminate and closing the joint. A method for manufacturing an amorphous winding core transformer that constitutes a transformer, wherein, when sequentially joining both ends of each unit laminate, uncured resin is attached to the end of each unit laminate and the joint is closed. It is characterized in that the resin is hardened after being cured.

[0006]

As described above, if the end portions of the unit laminated body are hardened with the resin, it is possible to prevent fragments of the magnetic material from being generated from the cut surface of each unit laminated body which is most likely to be chipped. for that reason,
The largest cause of debris can be eliminated, and the cover covering the iron core can be simplified to reduce the cost of the transformer.

[0007]

EXAMPLE In the example of the present invention, a rectangular amorphous winding iron core C as shown in FIG. 7 is first formed by using a ribbon of an amorphous magnetic material.

In order to form this wound core, first, as shown in FIG. 2, an amorphous magnetic alloy ribbon F is formed on a circular mandrel Q.
Is wound until a predetermined winding thickness T is obtained to form a ring-shaped laminated body R.

Next, as shown in FIG. 3, holding plates H1 and H2 are respectively applied to the inner peripheral side and the outer peripheral side of a part of the ring-shaped laminated body R, and these holding plates H1 and H2 are clamped by a vise force or the like. After tightening, the holding plates H1 and H2 and the ring-shaped laminated body R are cut in the laminating direction at the central portions in the lengthwise direction of the holding plates H1 and H2 (portions indicated by broken lines Ct in the figure). At the time of this cutting, a grindstone cutter G made of a thin grindstone disk is used, and the cutter G is moved in the stacking direction of the stack R while rotating the cutter G at high speed around the rotation axis X. Due to this cutting, the holding plates H1 and H2 are respectively halved H11,
It is divided into H12, H21 and H22.

After cutting the ring-shaped laminate R as described above, one half of the cut holding plate, for example, half H
While keeping 11 and H21 clamped, the clamps of the other half H12 and H22 are released, and the laminated body is linearly developed as shown in FIG. The developed laminated body is referred to as a developed laminated body S. The cut surface a at one end constrained by the holding plate of the expanded laminated body S is a laminated surface perpendicular to the longitudinal direction of the laminated body S, and the cut surface b at the other end is the laminated body S.
The laminated surface is inclined with respect to the longitudinal direction.

After forming the expanded laminated body S, the half portions H11 and H21 of the holding plate are removed as shown in FIG.
By separating the thin strips F constituting the above-mentioned structure into predetermined thicknesses, the expanded laminated body S is divided into a plurality of unit laminated bodies U.
The separated unit laminate bodies U are represented by symbols U1, U2, ... In order from the shortest one.

Next, several unit laminates with consecutive numbers are used to assemble the laminate blocks B1, B2, .... In this embodiment, four unit laminates are used to assemble one laminate block, and the unit laminates U1 to U4 and U5 to U8 are assembled.
, A laminated block formed by B1,
B2, ...

In each laminated body block, the unit laminated bodies are arranged on the surface plate in order from the shortest one with reference to the respective positions, and the displacement dimension Δ
It is constructed by stacking by shifting by Ls in the longitudinal direction. For example, when forming the laminated block B1,
As shown in FIG. 6, first, the unit laminate U1 is formed into a thin strip F thereof.
Place the short side facing down on a surface plate (not shown).
Next, the unit laminated body U2 is stacked on the unit laminated body U1 with the short ribbon side facing downward. At this time, the position of the cut surface a of the unit laminated body U2 is displaced by .DELTA.Ls in the longitudinal direction with respect to the position of the cut surface a of the unit laminated body U1.

In the same manner, the unit laminate U3 is replaced with the unit laminate U
The position of the unit block U1 is shifted in the longitudinal direction and stacked, and the unit laminate U4 is stacked on the unit laminate U3 with the position thereof shifted in the lengthwise direction to complete the laminate block B1. Laminate blocks B2, B3, ...
To form.

After forming the plurality of laminated body blocks as described above, the plurality of laminated body blocks are circularly wound in order from the shortest length to the outer peripheral length equal to the inner peripheral length of the winding core. Then, both ends of each unit laminated body in each laminated body block are overlapped and bonded to each other to form a circular iron core.
Next, this circular iron core is formed into a rectangular shape and then magnetic field annealed to obtain a rectangular wound iron core C as shown in FIG. This rectangular wound iron core comprises yoke portions C1 and C3 and legs C2 and C4, and one of the yoke portions C1 has a lap joint J.

FIG. 8 shows the structure in the vicinity of the superposed joint portion. In this example, three laminated body blocks B1 to B3 are shown.
Form an iron core C. Both ends of each unit laminate are joined in a state of overlapping each other with a predetermined overlap margin, and the cut surface of each unit laminate faces the cut surface of an adjacent unit laminate with a gap g.

The number of laminate blocks forming the iron core is arbitrary. Further, when the required number of laminated body blocks cannot be obtained from one ring-shaped laminated body R, a plurality of ring-shaped laminated bodies having different diameters are manufactured, and the unit laminated body and the laminated body are laminated by the same method as described above. Build body blocks.

In the above description, the unit laminate bodies U1, U2,
Although both ends of each of the unit laminates are superposed and joined, the ends of each of the unit laminate bodies U1, U2, ... May be butt joined via a gap.

In the above description, a method of forming a ring-shaped laminated body R and cutting the laminated body R with a grindstone cutter to obtain a unit laminated body is adopted. It is also possible to adopt a method of cutting the thin strips laminated to a predetermined thickness to form a unit laminated body without winding in a ring shape.

After the wound core C as shown in FIG. 7 is formed as described above, the wound core C is placed in an annealing furnace and annealed. After annealing, as shown in FIG. 1 (A), the joint portion J of the wound core is
At least the laminated surface of the U-shaped portion other than the yoke portion C1 and the edge portions at both ends thereof are covered with a cover K, and the U-shaped metal frame body M1 is fitted inside the U-shaped portion. Then, the joint J is opened, and the windings W1 and W2 are fitted to the legs C2 and C4.

Next, a shallow U-shaped frame M2 forming a rectangular frame together with the frame M1 in the window of the wound core is butted against the ends of the frame M1, and both ends of the unit laminated bodies U1, U2 ,. The joining portion J of the yoke portion C1 of the wound core C is closed by sequentially rejoining. As shown in FIG.
As shown by hatching in (B), both ends of each unit laminate are sequentially re-bonded while applying the uncured resin P to each end face (cut surface) of each unit laminate in order.

After the joint J is closed, the resin P is hardened. After that, a cover is attached so as to cover at least the laminated surface of the yoke portion C1 and the edge portions at both ends thereof to complete the transformer main body.

When the resin is applied to the end surface of each unit laminate body and cured as described above, the end portion of each unit laminate body is hardened with the resin, so that even if an impact is applied to the end portion of each unit laminate body. Since it is not easily chipped, it is possible to prevent the fragments of the magnetic material from being generated from the end of each unit laminate.

As the resin P, it is preferable to use one that satisfies the following conditions.

Do not penetrate deeply between the ribbons of amorphous magnetic material.

The film thickness as applied is thin.

It should have a viscosity such that excess resin can easily escape when the unit laminate is pressed by hand.

The coating should improve the slip of the ribbon of the amorphous magnetic material.

The curing time is longer than the time required to close the joint, and the resin does not cure during the operation.

The resin P may be hardened after being hardened, but in order to keep iron loss low, it is preferable to use a resin having flexibility after hardening.

As a resin satisfying the above conditions, for example, Pryobond # 30 (trade name) manufactured by ASHLAND CHEMICAL can be used.

In the above description, the resin P is applied to the end face of each unit laminate, but in the present invention, the resin is attached to the end face of each unit laminate so that the end portion of each unit laminate is made of resin. The resin may be attached to the end face of each unit laminate by a method other than coating. For example, the resin may be sprayed onto the end surface of each unit laminate.

[0033]

As described above, according to the present invention, since the end portions of the unit laminated body are hardened with the resin, it is possible to prevent the fragments of the magnetic material from being generated from the cut surface of each unit laminated body which is most liable to be chipped. Can be prevented. Therefore, there is an advantage that the largest factor causing the fragments can be eliminated, and the cover for covering the iron core can be simplified to reduce the cost of the transformer.

[Brief description of drawings]

FIG. 1A is a front view showing a state in which a joint portion of a wound core is closed in a manufacturing method of the present invention. (B) is an enlarged perspective view of a main part showing a structure of a joint portion of a wound iron core used in an embodiment of the present invention.

FIG. 2 is a front view showing a state in which a ribbon of amorphous magnetic material is wound to form a ring-shaped wound body.

FIG. 3 is a front view showing a state in which a part of the wound body of FIG. 2 is restrained and cut.

FIG. 4 is a front view showing a state in which a cut wound body is unfolded and partially omitted.

FIG. 5 is a front view showing a state in which a restraint tool has been removed from the developed laminated body, with a part thereof omitted.

6 is a front view showing a state in which unit laminates separated from the laminate of FIG. 5 are laminated to form a laminate that constitutes one iron core block.

FIG. 7 is a front view of a wound iron core used in the present invention.

FIG. 8 is a front view of a main portion showing an example of the structure of the joint portion of the wound iron core of FIG. 7.

[Explanation of symbols]

C ... Winding iron core, C1 ... Yoke portion having joints, C2, C4
... Legs, U1 to U12 ... Unit laminate, J ... Joint, W1,
W2 ... Winding, P ... Resin.

Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location H01F 41/06 8019-5E

Claims (2)

[Claims] 1. A plurality of unit laminates formed by laminating a predetermined number of thin strips of an amorphous magnetic material are laminated, and joints at both ends of each unit laminate are distributed stepwise on one yoke portion. An amorphous winding iron core transformer comprising an amorphous winding iron core and a winding fitted to the winding iron core, characterized in that each end of each unit laminate is hardened with resin. vessel. 2. A plurality of unit laminated bodies formed by laminating a predetermined number of thin strips of amorphous magnetic material are laminated, and the joints at both ends of each unit laminated body are distributed stepwise on one yoke portion. A transformer is formed by forming an amorphous winding iron core, opening the joint of the winding iron core, fitting the windings to the legs of the winding iron core, then sequentially joining both ends of each unit laminate and closing the joint. In the method for manufacturing an amorphous winding core transformer, which comprises, when joining both ends of the unit laminate, uncured resin is attached to the end of each unit laminate, and the resin is formed after closing the joint. A method for manufacturing an amorphous winding iron core transformer, characterized in that: