JPH0727825B2 - Iron core using amorphous metal thin film, method of manufacturing the same, transformer and reactor using the same - Google Patents

Description

TECHNICAL FIELD The present invention relates to an iron core using an amorphous metal (amorphous) thin film, a method for manufacturing the iron core, and a transformer and a reactor using the iron core.

[Prior Art] Iron cores are used for transformers and reactors.

Taking a transformer as an example, a transformer uses electromagnetic induction between magnetically coupled windings to transform an alternating voltage or current into a certain ratio, resulting in power transformation. Is. In the current electric power system, the electric power generated by the alternator is boosted by the power transformer installed in the power plant, sent to the primary substation in the suburbs of the city via the high voltage transmission line, and is stepped down there. Sent to the city,
It will be reduced to the required voltage by the distribution transformer installed in the secondary substation. Transformers are often used for such power transformation.

Recently, small transformers have been developed as high frequency transformers.

An example of the above-mentioned conventional transformer will be described with reference to the drawings.

FIG. 7 shows a principle model diagram of a transformer generally used in a power plant or a substation. When the primary winding and the secondary winding are arranged in the iron core and the power is turned on from the input terminal on the primary winding side, the target voltage / current can be obtained from the output terminal on the secondary winding side. As an iron core of such a conventional transformer, a laminated one of silicon steel plates or a coiled product having slit slit grooves S as shown in FIG. 8 is used.

Further, a leg iron core used in a high frequency transformer will be described as another known technique. As shown in FIG. 8, the leg iron core 11 is a wound body of an amorphous metal (amorphous) thin film having a thickness of several tens of microns, and a resin is filled between the thin films. When this leg iron core 11 is used in a transformer for an inverter, a slit cutting groove S having a width of several millimeters is provided in order to prevent a short circuit such as a magnetic bias.

As another known technique, a reactor iron core having a function of a static device as an inductance element of an electric circuit is provided with a Bach function in the case of instantaneous voltage application. Therefore, as shown in FIG. A slit cutting groove S having a width of several millimeters was provided.

As shown in FIG. 9, the iron core of the prior art used for the above-mentioned transformer and reactor is wound into a thin film (process A), annealed to keep the wound shape and remove the strain (process B), and integrated shape. In order to maintain the temperature, a resin (adhesive) is vacuum-filled (step C), the adhesive is dried (step D), slits are cut (step E), and the cut portion is polished (step F). I needed a process.

Further, a toroidal coil (circular core) formed by winding an amorphous magnetic thin piece is disclosed in JP-A-59-136917. Further, a wound core formed by winding an amorphous magnetic ribbon and forming a rectangular shape by using a rectangular reinforcing frame is disclosed in
It is disclosed in Japanese Patent Publication No. 59-172957.

[Problems to be Solved by the Invention] However, a slit cutting groove S having a width of several millimeters is provided in a wound body of an amorphous metal (amorphous) thin film as shown in FIG. 8 (step C in FIG. 9). ) Has a problem that the Vickers hardness of the amorphous metal thin film is as high as about 900 (Vickers hardness is about 210 for ordinary silicon steel sheet), and it is difficult to cut because it is hard. For this reason, even if an expensive cutting tool such as a diamond cutter is used, it is still difficult to cut, and the cutting cost is high.

Further, in the above-mentioned conventional technique, since a series of working steps such as an annealing step (step B), a slit cutting step (step E), and a step of polishing a cut portion (step F) are required, an amorphous metal thin film is formed. There was a problem that the original iron loss efficiency was lowered and the original characteristics could not be utilized. Especially because the physical distortion due to the slit cut cannot be completely recovered.

Further, there is also a problem that the wound body is easily collapsed between the winding of the thin film (step A) and the filling of the resin (step C), and the handling is troublesome.

Further, JP-A-59-136917 discloses a toroidal coil (circular core), and JP-A-59-172957 discloses a rectangular core using a reinforcing frame, both of which are used for integrally assembling a plurality of iron cores. There is a problem that it is not suitable for, and there is a problem that a hole for inserting a bolt must be provided at the time of mounting.

The present invention, in order to solve the problems of the prior art, is an iron core as a flattened winding body in which an amorphous metal thin film is rolled up, flattened, and filled with a resin, and the iron core has no slit cutting traces. The first object of the present invention is to provide an iron core having high iron loss efficiency and other high quality characteristics, and also to rationalize the manufacturing process to reduce the manufacturing cost and a manufacturing method thereof. And

A second object of the present invention is to provide a transformer and a reactor using the iron core having excellent quality characteristics described above and having a low manufacturing cost.

[Means for Solving the Problems] In order to achieve the above object, an iron core using an amorphous metal thin film of the present invention is an iron core using an amorphous metal thin film, and the amorphous metal thin film is A flattened winding body that is rolled up and is flattened with a core portion made of a plastically deformable object and is filled with resin, and a bolt is inserted between the core portion and the flattened winding body. And the flattened winding body has no slit cutting trace. In the above, for the core portion made of a plastically deformable object, the above-mentioned amorphous metal thin film wound body or the like can be used.

Next, the method for producing an iron core using the amorphous metal thin film of the present invention is a method for producing an iron core using the amorphous metal thin film,
First, an amorphous metal thin film is wound up, then the wound body is flattened by a press together with a core portion made of a plastically deformable object, and a bolt is inserted between the core portion and the flattened winding body. It is characterized in that a gap is present to form a flattened wound body, and then the flattened wound body is filled with resin.

Next, a transformer using the amorphous metal thin film of the present invention is a transformer including at least a leg core, yoke cores existing above and below the leg core, and a coil around the leg core, wherein At least a part of the iron core of the transformer is a flattened winding body in which a thin film made of an amorphous metal is rolled up, is flattened together with a core portion made of a plastically deformable object, and is filled with resin, and the core is There is a gap for inserting a bolt between the portion and the flattened winding body, and the flattening winding body is an iron core having no slit cutting traces.

In the above structure, it is preferable that the leg core and the upper and lower yoke cores are provided with a space of 0.01 to 1 mm.

Moreover, in the said structure, it is preferable to make a heat resistant sheet or film exist between a leg iron core and the yoke cores which exist above and below.

Next, the reactor using the amorphous metal thin film of the present invention is a leg iron core, a yoke core existing above and below the leg iron core, and a reactor including at least a coil around the leg iron core. At least a part of the iron core is a flattened winding body in which a thin film made of an amorphous metal is rolled up, is flattened together with a core portion made of a plastically deformable object, and is filled with resin. There is a gap for inserting a bolt between the flexible winding body, and the flattening winding body is an iron core without slit cutting traces,
It is characterized in that the interval between the leg core and the yoke cores existing above and below is set in the range of 0.5 to 10 mm.

In the above configuration, it is preferable that a heat resistant sheet or film is present between the leg core and the yoke cores present above and below.

[Operation] According to the configuration of the invention of claim 1 of the present invention described above, the iron core is a flat wound body in which an amorphous metal thin film is rolled up, flattened, and filled with resin, and the iron core is Since there is no slit cut mark, the iron core has high iron loss efficiency and high quality characteristics. The reason for this is that if a slit cut is made in the iron core, distortion will always occur, and the iron loss efficiency originally possessed by the amorphous metal thin film cannot be exhibited. This is because it is unnecessary.

Next, according to the configuration of the invention of claim 2 of the present invention, not only the conventional 6-step manufacturing process is simplified to 4 steps, but also the slit of the winding body of the amorphous metal thin film having high hardness is formed. Since the cutting process is eliminated, the manufacturing cost can be reduced. Further, since the winding body is flattened and then the resin is filled, the winding body does not collapse and the resin filling work can be facilitated. It should be noted that the step of drying the adhesive is broadly referred to as a step in which the effect of adhering the adhesive can be exerted by adopting a room temperature or heating effect.

Next, according to the configuration of the invention of claim 3 of the present invention described above, since the iron core having excellent quality characteristics described above is used, the quality such as the iron loss efficiency of the transformer itself is excellent and the size can be reduced. Exert an effect. Also, the manufacturing cost can be reduced.

Next, according to the configuration of the invention of claim 4 of the present invention described above, in the above-mentioned transformer, since the interval between the leg iron core and the upper and lower yoke cores is set to 0.01 to 1 mm, the magnetic flux for the inverter is demagnetized. A short circuit can be prevented.

Next, according to the configuration of the invention of claim 5 of the present invention described above, in the above-mentioned transformer, a heat-resistant sheet of aromatic polyamide, polyimide, or the like is provided between the leg core and the yoke cores existing above and below. Since the film is present, the distance between the leg iron core and the upper and lower yoke cores can be accurately determined.

Next, according to the above-mentioned structure of the invention of claim 6, at least a part of the core of the reactor is flattened by winding up a thin film made of an amorphous metal and filled with a resin. It is a wound body, the flattened wound body is an iron core without slit cutting traces, and by providing the interval between the leg core and the yokes existing above and below by 0.5 to 10 mm,
Since the above-described iron core having excellent quality characteristics is used, the reactor itself has excellent quality such as iron loss efficiency and can be miniaturized. Also, the manufacturing cost can be reduced.

Next, according to the configuration of the invention of claim 7 of the present invention described above, in the reactor, between the leg core and the yoke cores present above and below, a heat-resistant sheet or film of aromatic polyamide, polyimide or the like is provided. Since they are present, the distance between the leg core and the upper and lower yoke cores can be accurately determined.

[Embodiment] An embodiment of the present invention will be described more specifically below with reference to the drawings. The present invention is not limited to the following example.

FIG. 1 shows an iron core of the present invention and a method for manufacturing the same. That is, FIG. 1 (a) shows a flattened wound body 2 in which one plastically deformable body 10 is placed in the core of a wound body 1 in which an amorphous metal thin film is wound up and flattened by a press. . FIG. 1B is a plan sectional view of the flattened winding body 2. FIG. 1C is a front view of the flattened winding body 2. This iron core is mainly suitable for single-phase iron cores.

1 (d) to (f) show another method for manufacturing the iron core of the present invention. That is, FIG. 1 (d) shows that two plastically deformable objects 10 and 10 are placed in the core of the winding body 1 in which an amorphous metal thin film is wound up and flattened by a press to flatten the winding body (iron core) 2 It is what FIG. 1E is a plan sectional view of the flattened winding body 2. FIG. 1 (f) is a front view of the flattened winding body 2. This iron core is mainly suitable for a three-phase iron core.

In FIG. 1, the amorphous metal thin film of the wound body 1 may be of any type as long as it is generally called an amorphous high magnetic permeability material. For example, it is preferable that the composition is Fe ₇₈ B ₁₃ Si ₉ and the thin film has a thickness of about 25 μm. More specifically, such a material is "METGLAS2605S-2" (trade name) manufactured by Nippon Amorphous Metal Co., Ltd.
As another example, "Handbook of Electrical and Electronic Materials",
Those described in pages 874 to 876 (published by Asakura Shoten on November 15, 1987) can be used.

The winding width of the winding body 1 is, for example, 25 mm or 50
It can be mm. For example, when a thin film having a thickness of about 25 μm is used, the number of times of winding can be 400 turns and the laminated thickness can be about 10 mm.

The size of the flattened winding body 2 is, for example, 200 m in length.
m, height 50 mm, depth 50 mm.

In FIG. 1, the winding section is wound into a substantially circular shape and then flattened, but it goes without saying that the iron core of the present invention may be wound into a flat shape from the beginning.

Next, FIG. 2 will be described. FIG. 2 shows a method for manufacturing an iron core according to the present invention. First, the amorphous metal thin film is wound up (step A), then the wound body is flattened by a press to form a flattened wound body (step P), and then a resin (adhesive) is applied to the flattened wound body. Filling is performed by a vacuum filling method or the like (step C), and thereafter, the adhesive is dried (step D). Of course, the inclusion of other steps is not excluded.

As a result, the conventional 6 manufacturing steps (Fig. 9) are replaced by 4 manufacturing steps.
Not only was the process simplified (FIG. 2), but the slit cutting process of the winding body of the amorphous metal thin film having high hardness was eliminated, so that the manufacturing cost could be reduced. Further, since the winding body is flattened and then the resin is filled, the winding body does not collapse and the resin filling work can be facilitated.

In the resin filling step (step C) of FIG. 2, for example, epoxy resin, silicon resin, phenol novolac resin, etc. are used to fill the resin between the thin films by a vacuum method or the like, and the resin is cured at room temperature or by heating. Including that. In the case of heat drying, for example, temperature: 170 ° C., time: about 2 hours can be adopted.

FIG. 3 is an embodiment showing a single-phase transformer or reactor using the iron core of the present invention, and FIG. 4 is its assembly drawing.

First, explaining from the assembly drawing of FIG. 4, the leg cores 3a, 3b
2 of them are arranged almost parallel to each other, and one end thereof is yoke cores 4a and 4c.
Assemble so that the other end is sandwiched between the yoke cores 4b and 4d.

Next, referring back to FIG. 3, the description will be made with reference to FIG. 3 which is assembled as shown in FIG. 4, and FIG. 3 (a) is a plan view.
3 (b) is a front view and FIG. 3 (c) is a side view.
In FIG. 3, 3a and 3b are leg cores, 4a, 4b, 4c and 4d are yoke cores, 5 is a coil (winding body), 6 is a bolt-nut made of non-magnetic material such as stainless steel, and G is constant. The interval is 0.5 to 10 mm in the case of a reactor,
In the case of a transformer, it is preferable to provide a space of 0.01 to 1 mm. A heat resistant sheet or film of aromatic polyamide, polyimide or the like is preferably present in the gap G. For example, the product name of DuPont, USA, "Nomex"
The interval can be set accurately by using paper or film. Also, the thickness of the yoke core is the height W of the leg core.
It is preferably about 1/2 of

Next, FIG. 5 and FIG. 6 are assembly diagrams of a three-phase transformer or reactor using the iron core of the present invention. FIG. 6 corresponds to FIG. 4, and differs from FIG. 4 in that three leg iron cores are used. Further, FIG. 5 (a) is a plan view, FIG. 5 (b) is a front view, and FIG. 5 (c) is a side view. The description is omitted because it is the same as that in FIG. 3 except that three leg iron cores are used.

According to the above-described embodiment of the present invention, "METGLAS2605S-2" (trade name) (amorphous alloy) manufactured by Nippon Amorphous Metal Co., Ltd. has a thickness of 25 μm and a width of 25 mm. 1KHz, in 1.0wb (Weber) / m ^2, 5.3w / k
In contrast to g, the iron loss value of the iron core of the example of the present invention was 6.2 w / kg. On the other hand, the iron loss value of the core obtained by slit cutting according to the conventional technique was 8.5 w / kg.

From the above examples, it was confirmed that the iron loss efficiency of the iron core of the present invention was excellent.

Therefore, in combination with the magnetic properties of amorphous alloys, that is, high magnetic permeability, low loss, large electrical resistivity, and small thickness, the eddy current loss is small, which makes the magnetic alloy excellent in high frequency. It was possible to realize an iron core having characteristics, and it was possible to realize a transformer and a reactor having excellent characteristics by using this iron core.

[Effects of the Invention] As described above, the iron core of the present invention is an iron core that is a flattened winding body in which an amorphous metal thin film is rolled up, flattened, and filled with resin, and the iron core has slit cutting traces. Since there is no iron, it is possible to achieve a special effect that the iron core has high iron loss efficiency and high quality characteristics. The reason for this is that if a slit cut is made in the iron core, distortion will always occur and the iron loss efficiency originally possessed by the amorphous metal thin film will be greatly reduced. This is because it is unnecessary. Further, the iron core of the present invention is flattened together with a core portion made of a plastically deformable object, and there is a gap for inserting a bolt between the core portion and the flattened winding body,
It is extremely easy to assemble and fix the iron cores together.

Next, the iron core manufacturing method of the present invention not only simplifies the conventional 6-step manufacturing step to 4 steps, but also eliminates the slit cutting step of the winding body of the amorphous metal thin film having high hardness. The special effect of being able to lower costs can be achieved. Further, since the rolled-up body is flattened and then filled with the resin, the rolled-up body does not collapse and the resin filling work can be facilitated.

Next, since the transformer of the present invention uses the above-described iron core having excellent quality characteristics, it is possible to achieve an effect that the transformer itself has excellent quality such as iron loss efficiency and can be miniaturized. Also, the manufacturing cost can be reduced.

Next, since the reactor of the present invention described above uses the iron core having excellent quality characteristics described above, it is possible to achieve an effect that the reactor itself has excellent quality such as iron loss efficiency and can be miniaturized. Also, the manufacturing cost can be reduced.

[Brief description of drawings]

FIG. 1 shows an iron core according to an embodiment of the present invention and a manufacturing method thereof, FIG. 2 shows a manufacturing process of the iron core according to an embodiment of the present invention, and FIG. 3 is a single phase using the iron core of the present invention. 4 is an assembly diagram thereof, and FIG. 5 is an example showing a three-phase transformer or reactor using the iron core of the present invention. , FIG. 6 is an assembly diagram thereof, FIG. 7 shows a principle model diagram of a conventional transformer, FIG. 8 shows a conventional iron core,
FIG. 9 is a diagram showing a manufacturing process of a conventional technique. 1: Winding body of amorphous metal thin film 2: Flattened winding body (iron core) 3a, 3b: Leg core 4a, 4b, 4c, 4d: Yoke core 5: Coil (winding body) 6: Non-magnetic bolt − Nut G: Constant spacing S: Slit

Claims (7)

[Claims] 1. An iron core using an amorphous metal thin film, wherein the amorphous metal thin film is rolled up, flattened together with a core portion made of a plastically deformable object, and filled with resin. In addition to being a body, there is a gap for inserting a bolt between the core portion and the flattened wound body, and the flattened wound body has no slit cut mark. Iron core using amorphous metal thin film. 2. A method of manufacturing an iron core using an amorphous metal thin film, which comprises first winding up an amorphous metal thin film, and then flattening the wound body together with a core made of a plastically deformable body by pressing. A gap for inserting a bolt is present between the core portion and the flattened winding body to form a flattened winding body, and thereafter, the flattened winding body is filled with resin. A method for manufacturing an iron core using a characteristic amorphous metal thin film. 3. A transformer including at least a leg core, yoke cores above and below the leg core, and coils around the leg core, wherein at least a part of the core is amorphous. A thin film made of metal is rolled up, and is flattened with a core portion made of a plastically deformable object, and is a flattened winding body filled with resin, and between the core portion and the flattened winding body. A transformer using an amorphous metal thin film, characterized in that there is a gap for inserting a bolt, and the flattened winding body is an iron core with no slit cut marks. 4. The distance between the leg core and the upper and lower yoke cores
The transformer using the amorphous metal thin film according to claim 3, which is provided in a range of 0.01 to 1 mm. 5. Between the leg core and the upper and lower yoke cores,
The transformer using the amorphous metal thin film according to claim 3, wherein a heat resistant sheet or film is present. 6. A reactor including at least a leg core, yoke cores present above and below the leg core, and a coil around the leg core, wherein at least a part of the core of the reactor is an amorphous metal. Is a flattened winding body that is flattened with a core portion made of a plastically deformable object and is filled with resin, and a bolt is provided between the core portion and the flattened winding body. There is a gap to insert,
And the flattened winding body is an iron core without slit cut marks, and the gap between the leg iron core and the upper and lower yoke cores is
A reactor using an amorphous metal thin film characterized by being provided in a range of 0.5 to 10 mm. 7. Between the leg core and the upper and lower yoke cores,
A reactor using the amorphous metal thin film according to claim 6, wherein a heat resistant sheet or film is present.