KR0173143B1 - Reactor and method for manufacturing the same - Google Patents

Abstract

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reactor for use in electrical and electronic equipment, and aims to improve cooling performance and to provide iron cores of optimum dimensions for each model. Two sets of iron cores 1 and coils 2 made together are arranged side by side, and are opposed to two iron cores 4 formed by laminating a trapezoidal electromagnetic steel sheet via a core gap spacer 3. Form a path to the statue. Two iron cores 4 located at the outer side of the four iron cores are connected and fixed to each other by the fixing member 5. By adopting such a configuration, the coil is divided into two to increase the surface area of the coil, so that the cooling performance is improved, and the shape of the electromagnetic steel sheet used for the iron core can be made simple. Therefore, the electromagnetic steel sheet of various sizes can be easily manufactured. In addition, it becomes possible to provide the iron core of the optimum dimension for every model.

Description

Reactor and its manufacturing method

1 is a cross-sectional view of a reactor as a first embodiment of the present invention.

2 is an explanatory diagram of an electromagnetic steel sheet used for the iron core of the reactor.

3 is an explanatory diagram of a manufacturing process of the copper steel sheet.

4 is an explanatory diagram of a lamination direction of iron cores of the reactor.

5 is an explanatory diagram of a lamination direction of iron cores of the reactor.

6 is a relationship between the pressure applied to the core gap spacer of the reactor and the inductance value of the reactor.

7 is a sectional view of a reactor as a second embodiment of the present invention.

8 is an explanatory diagram for insulation of the coil of the reactor.

9 is a sectional view of a reactor as a third embodiment of the present invention.

10 is an explanatory diagram of a reactor as a fourth embodiment of the present invention.

11 is an explanatory diagram of a reactor as a fifth embodiment of the present invention.

12 is an explanatory diagram of a reactor as a sixth embodiment of the present invention.

13 is an explanatory diagram of a reactor as a seventh embodiment of the present invention.

14 is an explanatory diagram of a reactor as an eighth embodiment of the present invention.

15 is a cross-sectional view of a conventional reactor.

FIG. 16 is an explanatory diagram of a manufacturing process of an electromagnetic steel sheet used for iron cores of the reactor. FIG.

* Explanation of symbols for main parts of the drawings

1,4,16,19,22,25,102,104: Iron core 2,17,23,105: Coil

3,18,24: core gap spacer 5,21,28: fixing member

5a: Mounting parts to other equipment in the fixing member

6,101,103; Electromagnetic steel sheet 7: cut part of the electromagnetic steel sheet

8,20,26,27: Coil insulation paper 9,29,110: Mounting plate for other equipment

10: cladding part between coils 11: resin molding part

11a: Terminal fixing part of the resin molding part

11b: Mounting part for other equipment attached to the resin molding part

12,15 Terminal 13: Reactor main body

14: resin molding layer 14a: terminal fixing part of the resin molding layer

14b: Mounting portion for other equipment mounted on the resin mold layer

29a: Iron core mounting portion of the mounting plate 106: Core gap portion of the iron core

107: core fitting portion 108: core gap portion of the electromagnetic steel sheet

109: cutting line in the production of electromagnetic steel sheet

The present invention relates to a reactor used for electrical and electronic equipment.

Conventional reactors, as shown in FIGS. 15 and 16, have an iron core 102 in which an E-shaped electromagnetic steel sheet 101 is laminated, and an iron core 104 in which an I-shaped electromagnetic steel sheet 103 is laminated. The coil 105 is incorporated in them, and the core gap 106 is formed in the E-type iron core 102 in advance. The two iron core fitting portions 107 are fixed by welding or the like. In addition, the mounting plate 110 for other equipment is also attached to the iron core 102 by welding or the like.

In general, the dimensions of the E-shaped and I-shaped electromagnetic steel sheets 101 and 103 are in the ratio shown in FIG. 16, and the loss of the electromagnetic steel sheet material during the punching of the electromagnetic steel sheet is considered to be minimum. In other words, two sheets of the I-shaped electromagnetic steel sheet 103 and the core gap portion 108 are first punched by the H-type punching mold, and the remainder is cut by the cutting line 109, thereby forming the E-type and I-shaped electromagnetic steel sheet 101. (103) is generated simultaneously two pieces each. Material loss of the electromagnetic steel sheet does not occur except the core gap portion 108.

However, since the punching of the electromagnetic steel sheets 101 and 103 requires a very expensive mold, the kind of the size of the electromagnetic steel sheets 101 and 103 is limited. For this reason, when making a reactor using the conventional E-type and I-shaped electromagnetic steel plates 101 and 103, one of the several types of punched electromagnetic steel sheets of the standard dimension prepared is selected. That is, even if the size of the electromagnetic steel sheets 101 and 103 is too large with respect to the size of the coil 105, the selected electromagnetic steel sheets 101 and 103 are inevitably forced to be used in many cases. It was difficult to make the optimum material design of the cores 102 and 104 in terms of cost.

In general, this type of reactor is often placed in a place where cooling is not good in the built-in equipment, so as a reactor, the wire diameter of the coil 105 is thickened to reduce copper loss, or the core 102 ( The material of 104) was used to reduce the iron loss by reducing the iron loss.

The present invention solves such a conventional problem and aims to provide a reactor excellent in economy and productivity.

In order to achieve this object, the reactor of the present invention,

① Two first iron cores formed by stacking electromagnetic steel sheets respectively inserted through coils in parallel, and two second iron cores formed by laminating these and other electromagnetic steel sheets, face each other via a core gap spacer. It is formed of a chair.

(2) Parallel the two first iron cores formed by laminating the electromagnetic steel sheets inserted through the coils respectively, and the two second iron cores formed by laminating these and the other electromagnetic steel sheets face each other through the core gap spacer. A magnetic path is formed and two iron cores positioned at least outside of the first or second iron cores are fixed by fixing means.

(3) A core gap spacer having elasticity in at least the thickness direction of two first iron cores formed by stacking electromagnetic steel sheets respectively inserted through coils in parallel, and two second iron cores formed by laminating these and other electromagnetic steel sheets. Forming a magnetic path, and measuring the characteristics of inductance and the like, pressing the iron core to adjust the thickness of the core gap spacer, which is the core gap dimension, and pressing pressure when the required characteristics are obtained. It is intended to manufacture a reactor by means of fixing the iron core as it is maintained.

With the construction of the means ①, the coil is divided into two and the cooling surface area of the coil is increased, so that the temperature rise of the reactor is reduced. In addition, since the electromagnetic steel sheet can be made into a simple shape, the electromagnetic steel sheet can be easily produced by shearing or the like without using an expensive punching mold. Thereby, it becomes possible to change and employ | adopt the electromagnetic steel sheet of the minimum dimension required for accommodating a coil for every model.

Moreover, the structure of means (2) can provide a structure in which the entire reactor, such as an iron core and a coil, is securely fixed.

In addition, the thickness of the core gap spacer to secure the core gap dimension greatly influences the characteristics of the reactor. For this reason, very high precision is required as a thickness dimension of a core gap spacer, and a very expensive thing must be used as a material of a core gap spacer. However, by assembling with the manufacturing method described in the above means, it is possible to easily adjust the core gap dimension to give the required reactor characteristics by using a core gap spacer of inexpensive material having elasticity in the thickness direction.

Hereinafter, a reactor as a first embodiment of the present invention will be described with reference to FIG.

In addition, description is abbreviate | omitted about the point similar to a conventional example. In Fig. 1, the iron core 1, which is formed by laminating rectangular electromagnetic steel sheets and blocked by means of welding, protruding pressure welding, bonding, or the like, is inserted through the coil 2 and inserted therein. The combination of the iron core 1 and the coil 2 is arranged side by side, and is formed by laminating a trapezoidal electromagnetic steel sheet through a core gap spacer 3 made of an insulating sheet having elasticity in the thickness direction. The iron cores (4) of the dogs are assembled to form a □ -shaped magnetic path. The magnetic flux generated by the two coils 2 connected in a positive polarity, the? -Shape flows through the core through the core gap secured by the thickness of the core gap spacer 3, and provides characteristics as a reactor.

□ The iron core 4 located on the outside of the four iron cores 1 and 4 forming the magnetic path is welded and fixed by the fixing member 5 integrated with the mounting portion 5a to the other equipment. The varnish impregnation process is performed as a whole reactor.

With such a configuration, the coil 2 is divided into two, the cooling surface area of the coil 2 is increased, and the cooling property of the reactor is improved, so that the wire diameter of the coil 2 can be reduced to reduce the wire usage.

In addition, the electromagnetic steel sheet used for the iron cores (1) and (4) can be made into a rectangular or trapezoid with a simple shape, which eliminates the need for expensive punching molds, and can be easily produced by shearing, and the size of the electromagnetic steel sheet as compared with the conventional case. Can also be set freely. This makes it possible to design the required minimum dimensions with the dimensions of the iron cores 1 and 4 for accommodating the coil, thereby reducing the material usage of the iron cores 1 and 4.

In addition, as shown in FIG. 2, the magnetic steel sheet 6 used for the iron core 4 located on the outer side of the four cores 1 and 4 forming the magnetic path is shaped as a magnetic flux. The material used for the electromagnetic steel sheet 6 used for the iron core 4 is made into the shape which cut | disconnected the corner part 7 which is not valid. The angle of this trapezoidal electromagnetic steel sheet 6 is selected in the range of 60 degrees to 89 degrees from a practical characteristic point of view. An example in which the electromagnetic steel sheet 6 is produced without material loss is shown in FIG.

Also, as shown in Fig. 4, for the iron core 1 located inside of the four cores forming the self-shaped magnetic path, if the width A of the iron core 1 is larger than the depth B, the depth It is advantageous in terms of the punching processing ratio of the electromagnetic steel sheet to be used for the iron core 1 because the number of laminated sheets is so small that the dimension B becomes the lamination thickness of the iron core 1. In addition, the shape dimension of the electromagnetic steel sheet used for the iron core 1 in this case becomes a rectangle of AxB (B is the height dimension of the iron core 1).

On the other hand, when the width dimension A of the iron core 1 is smaller than the depth dimension B, as shown in FIG. 5, the width dimension A of the iron core 1 is laminated so that it becomes the lamination thickness of the iron core 1. Since the number of laminated sheets is at least, it is advantageous in terms of the punching processing ratio of the electromagnetic steel sheet used for the iron core 1.

In addition, the insulating sheet is used as the core gap spacer 3 necessary to secure the core gap, and serves as a function of securing the core gap size and the insulation, so that the insulation between the coil 2 and the iron core 4 can be obtained. No insulation sheet is required at all. In addition, the iron core 4 and the iron core 1 are insulated by an insulating sheet, and the iron core 1 is completely insulated from the iron core 4 which is grounded for mounting or the like. Therefore, the structure which does not require insulation of the iron core 1 and 4 of the coil 2 can be implement | achieved. This reduces the number of assembling steps by reducing the insulating material and simplifying the insulating structure. In addition, since the insulation of the coil 2 and the iron core 1 is not necessary as described above, the coil 2 can be wound directly on the iron core 1, thereby minimizing the inner diameter of the winding and reducing the wire material. At the same time, the number of manufacturing steps can be reduced by eliminating the need for the core jig and eliminating the separation work between the coil and the core jig after winding.

In addition, due to the limitations on the characteristics of the reactor, the thickness dimension of the core gap spacer 3 that secures the core gap requires considerable precision. In the case of this embodiment, the core gap dimension of one core gap is required to be 300 µm ± 10 µm, and very high cost is required to realize this dimensional accuracy with a material having no elasticity in the thickness direction. On the other hand, in this embodiment, an inexpensive material having elasticity in the thickness direction such as glass nonwoven fabric, polyester nonwoven fabric, aramid paper without calendering, etc. having a thickness sufficiently larger than the required thickness is used as the core gap spacer 3, and the core ( When 1) (4) is pressed and the core gap part is pressed, the thickness of the elastic core gap spacer 3, ie, the core gap dimension, changes according to the force. At this time, if the measuring device is connected to the coil 2 and the inductance value is measured at the same time, the pressure pressure and the inductance value become the relationship shown in FIG. Therefore, the reactor having the required inductance R can be easily manufactured by fixing the fixing member 5 as it is while maintaining the pressing force F corresponding to the required inductance R. In this way, the material cost can be reduced by using an inexpensive material having elasticity as the core gap spacer 3.

As the pressing force, it is also useful to use the electromagnetic force of the reactor itself in addition to mechanical means such as a press. That is, when electric power is supplied to the coil 2 and a current flows, a magnetic flux is generated in the? -Shaped magnetic path, and electromagnetic forces are drawn between the four iron cores 1 and 4 via the core gap portion, and the core gap is generated. The spacer 3 is pressed. When the voltage value V of the reactor is measured at the same time as the current value I energized by the coil 2 to generate the pressure, the inductance value ηH is V × 10 ³ / (2πf · I) in the case of an alternating current. (F represents the frequency of the energized power source). Therefore, the required inductance value can be calculated and obtained by adjusting the energized current while simultaneously measuring the voltage value V and the energized current value I. When the fixing member 5 is fixed as it is, the reactor having the required inductance value can be easily produced.

In addition, as shown in FIG. 1, two iron cores 4 located outside of the four iron cores forming the? -Shaped magnetic paths are attached to the fixing member 5 integrating the mounting portion 5a on another device. It is a structure connected by welding. Thereby, the whole reactor, such as the iron core 1 (4) and the coil 2, can be fixed reliably. In addition, the material of the fixing member can be reduced by using the fixing member structure which also has a mounting function to other equipment.

In addition, in the second embodiment, the configuration in the case where no insulating sheet is used as the core gap spacer 3 is shown in FIG. In addition, description is abbreviate | omitted about the point similar to the previous embodiment already, and the same also about the other Example shown below. In this case, insulation between the coil 2 and the iron cores 1 and 4 is necessary. As shown in FIG. 8, the coil insulation paper 8 is wound around the coil 2 to ensure insulation. do.

Moreover, in the structure shown in FIG. 9 as a 3rd Example, the reactor which was varnish-impregnated and hardened as it was pressed with the jig | tool etc. from the top and bottom is also useful. In general, varnish impregnation is performed for the purpose of rust prevention of iron core, suppression of magnetostrictive sound, moisture proof of coil insulation sheet, and the like. Adhesively fixed to the core gap spacer 3 in contact with each other, the entire reactor such as the iron cores 1, 4 and the coil 2 is fixed, and there is no need to use a fixing member for connecting two iron cores 4 in particular. It is possible to obtain a reactor of practical strength. In addition, the mounting plate 9 to other equipment is fixed by the iron core 4 and welding.

In addition, an example of a connection between two coils 2 is shown in FIG. 10 as a fourth example. The two coils 2 are connected in a positive polarity, but in such a case, the connection terminal is opposed to the winding end of one coil, which has already been cut during the integrated winding, and the winding start of the other coil, which is similarly cut. Connection process, such as crimp connection or winding these two leads together and soldered, was necessary. On the other hand, in this embodiment, like the hook 10, after winding the first coil, the winding end is not cut, and the second coil is wound as the winding start portion, thereby connecting as shown. Means are unnecessary. As a result, it is possible to eliminate materials such as connection terminals, solder, connection protection tubes, and the number of connection processing steps.

In addition, an example in the case where a part of the reactor of the present invention is molded by resin is shown in FIG. 11 as the example of FIG. By molding the iron cores 1 and 4 and the coils 2 with resin, they are fixed to the resin mold portion 11 and the terminal fixing portion 11a for fixing the terminal 12 to the resin molding portion 11 and other equipment. Can be easily provided with a mounting portion 11b, and the number of manufacturing steps can be reduced, and a mass-produced structure can be provided.

In addition, the example in the case where the whole reactor was molded with resin is shown in FIG. 12 as 6th Example. By resin-molding the entire reactor body portion 13 made of an iron core or a coil, the iron core and the coil are completely fixed by the resin mold layer 14 and are isolated and protected. A reactor structure that suppresses noise and vibration can be obtained. Moreover, the terminal fixing part 14a which fixes the terminal 15, the mounting part 14b to another apparatus, etc. can be provided easily, and it can be set as the structure which is very mass-produced.

In addition, as shown in FIG. 1, as shown in FIG. 1, the outer side of the iron cores 1 and 4 forming the? -Shaped magnetic path is not inserted into the iron core 4, that is, the coil 2, as shown in FIG. The iron core of has been explained. On the other hand, FIG. 13 shows an embodiment of the case where the iron core inserted into the coil is located outside, as the seventh embodiment.

In FIG. 13, an iron core 16 formed by laminating a trapezoidal electromagnetic steel sheet is inserted through a coil 17, and an iron core formed by laminating a rectangular electromagnetic steel sheet through a core gap spacer 18 made of an insulating sheet. Contrary to 19), they are forming a gyro. The iron core 16 is formed in the outer side of the four iron cores 16 and 19 which form a magnetic path. Since the iron core 19 is insulated from the earth by the insulating sheet 18 which also serves as the core gap spacer, the insulation between the iron core 19 and the coil 17 becomes unnecessary, but is located inside the coil 17. Since the iron core 16 is grounded via the fixing member 21, insulation therebetween is required, and the coil insulation paper 20 is attached. The two iron cores 16 on the outside are welded and fixed by the fixing member 21. Since both the operation and the effect of this embodiment are the same as in the first embodiment, detailed description thereof will be omitted.

The eighth embodiment will be described with reference to FIG. 14 with the first and second iron cores being trapezoidal, respectively.

The iron core 22 formed by laminating a trapezoidal electromagnetic steel sheet is inserted through the coil 23. Two sets of the combination of the iron core 22 and the coil 23 are arranged side by side, and a trapezoidal electromagnetic steel sheet is similarly laminated via the core gap spacer 24 having elasticity in the thickness direction. The two iron cores 25 are opposed to each other to form a □ -shaped magnetic path. Insulation between the coil 23 and the iron cores 22 and 25 is secured by the coil insulating papers 26 and 27. The iron cores 22 and 25 are fixed by welding the fixing member 28, the mounting plate 29 to another device, and the iron core mounting portion 29a formed by cutting a part thereof.

By such a configuration, the amount of wire material usage and iron core material usage can be reduced as in the case of the first embodiment. Further, since the iron core 22 and the iron core 25 can be trapezoidal in the same manner, the iron cores of the same shape and dimensions can be made completely, so that the manufacturing cost of the iron core can be reduced.

In addition, in this embodiment, the coil insulation paper 26 and the coil insulation paper 26 and 27 of the shape wound around the coil 23 as the insulation performed between the coil 23 and the iron cores 22 and 25 were used. It is also useful to construct insulation paper wound on 22) (25) or to perform insulation treatment such as resin coating on the surface.

As is apparent from the description of the above embodiment, the reactor of the present invention can reduce the wire diameter of the coil and reduce the wire usage because the coil is divided into two and the cooling surface area of the coil is increased to improve the cooling performance. In addition, since the shape of the electromagnetic steel sheet used for the iron core can be made a simple shape, expensive punching molds are unnecessary, and it is possible to easily and cheaply produce the electromagnetic steel sheet by shearing, etc. Can be adopted for each model, and the core material can be reduced.

In addition, this reactor includes four iron cores, two coils, a core gap spacer, and can securely fix the entire reactor by connecting two iron cores positioned outside of the first or second iron cores by fixing means.

In addition, the method for manufacturing the reactor adjusts the thickness of the core gap spacer, which is the core gap dimension, while measuring characteristics such as inductance values, and fixes the iron core by the fixing means as it is while maintaining the pressing force when the required characteristics are obtained. As the core gap spacer requires a very high precision thickness dimension, a very expensive material is required. An inexpensive material that does not require the thickness dimension precision can be used as the core gap spacer. The cost can be reduced.

Claims (15)

Core gap spacers having two first iron cores formed by stacking electromagnetic steel sheets respectively inserted through coils in parallel, and two second iron cores formed by laminating these and other electromagnetic steel sheets in a direction perpendicular to the magnetic flux direction. A reactor characterized in that a □ -shaped magnetic path is formed to face each other via a gap. The reactor according to claim 1, wherein the first or second iron core has one side sandwiched the other side, and an iron core positioned on the outside thereof is trapezoidal with the long side located inside. The reactor according to Claim 1, wherein the reactor is laminated in a direction in which the smaller dimension of the width dimension and the depth dimension becomes the lamination thickness with respect to the iron core located inside the first or second iron core. The reactor according to claim 1, wherein the core gap spacer is made of a material having elasticity in at least the thickness direction. The reactor according to claim 1, wherein an insulating sheet is used as the core gap spacer. The reactor according to claim 5, wherein the insulating sheet is made of a material having elasticity in at least the thickness direction. The reactor according to claim 1, wherein at least abutting portions of each iron core are fixed by varnish impregnation. The reactor according to claim 7, wherein the core gap spacer is made of a porous material or a fibrous material having elasticity in at least the thickness direction. A reactor according to claim 1, wherein the winding end portion of one coil is cut off without being cut off. The reactor according to claim 1, wherein part or all of the resin is molded or resin molded. The reactor according to claim 1, wherein the first and second iron cores each have a trapezoidal shape, and the inclined sides of the reactors face each other via a core gap spacer. Core gap spacers provided by parallel stacking of two first iron cores formed by laminating electromagnetic steel sheets inserted through the coils respectively, and two second cores formed by laminating these and other electromagnetic steel sheets in a direction perpendicular to the magnetic flux direction. A reactor characterized in that a? -Shaped magnetic path is formed to face each other, and two iron cores positioned at least outside of the first or second iron cores are fixed by fixing means. The reactor according to claim 12, wherein the fixing means is integrated with a mounting means for another device. Two first iron cores formed by laminating electromagnetic steel sheets inserted through the coils in parallel, respectively, and two second iron cores formed by laminating these and other electromagnetic steel sheets are elastically at least in the thickness direction, and the magnetic flux direction and The core gap spacers installed in the orthogonal direction are faced to each other to form a □ -shaped magnetic path, press the iron core while measuring characteristics such as inductance values, and adjust the thickness of the core gap spacers, which are core gap dimensions, and the required characteristics. A method of manufacturing a reactor, wherein the iron core is fixed by the fixing means as it is, while maintaining the pressing pressure at the time of obtaining this. The reactor manufacturing method according to claim 14, wherein an electromagnetic force generated by energizing the coil is used as a means for adjusting the thickness of the core gap spacer, which is the core gap dimension, by pressing the iron core.