JP5082811B2 - Reactor - Google Patents

Description

  The present invention relates to a reactor, and more particularly to a reactor having a core.

  FIG. 12 is a longitudinal sectional view illustrating a conventional reactor 90. Conventionally, a reactor 90 employing a so-called E-type core 91 and I-type core 92 has been put into practical use in an element using a coil 93 such as a power transformer. Here, a resin 95 is disposed between the center leg 94 of the E-type core 91 and the I-type core 92, and absorbs vibration during operation of the reactor 90. In addition, the flow of magnetic flux inside the reactor 90 is indicated by arrows.

JP 2007-123767 A

  However, the reactor 90 as described above has a problem that the E-type core 91 and the I-type core 92 collide with each other due to the vibration of the reactor 90 itself to generate noise. When the reactor 90 is configured using the E-type core 91 and the I-type core 92, there are three boundaries between the cores, and noise is generated even if the resin 95 is provided.

  In view of the above problems, an object of the present invention is to provide a technique for reducing noise.

  In addition, there is a problem that it is difficult to maintain the positional relationship between the cores in realizing the above object. Therefore, an object of the present invention is also to contribute to maintaining the positional relationship of the members constituting the reactor.

  In order to solve the above-mentioned problem, the first invention has an annular inner wall (14) exhibiting a through-hole (12), and at least one first recess (16) retreating with respect to the center of the through-hole An O-type core (10) formed on an inner wall; and an I-type core (20) having an end portion (22) extending across the through-hole and disposed to face the first recess. A reactor (100) comprising a coil (30) wound around the I-type core.

And it further comprises a cushioning member (40A～40i) disposed between the said end and the first recess (16) (22).

And, the said I-shaped core (20) extending direction the length along the buffer member (40a to 40e) is longer than the length along the extending direction of the first recess (16).

2nd invention is 1st invention, Comprising: The said buffer member (40b-40e) is a fitting body (42b, 42d, 42e) fitted to the said 1st recessed part (16), The said fitting body, A holding body (44b, 44d, 44e) that holds the I-type core (20) on the opposite side, and the cross-sectional area of the holding body in a plane perpendicular to the extending direction of the I-type core is: It is larger than the cross-sectional area of the fitting body in the plane.

3rd invention is 1st or 2nd invention, Comprising: The said I-type core (20) has a 2nd recessed part (24c) in the site | part which contact | connects the said buffer member, The said buffer member (40c) is the said Fits into the second recess.

4th invention is 1st or 2nd invention, Comprising: The said I type core (20) has a convex part (26d, 26e) in the site | part which contact | connects the said buffer member (40d, 40e), The said buffer The member is fitted with the convex portion.

  According to the first invention, the material of the I-type core around which the coil is wound and the material of the O-type core that functions as a yoke of the I-type core can be individually selected. Therefore, it is possible to suppress the cost while suppressing the temperature rise in the I-type core and increasing the efficiency of the reactor. Moreover, compared with the case where it comprises using an E-type core and an I-type core, the number of boundaries between the core around which the coil is wound and the core functioning as a yoke is reduced by one to reduce noise. Further, when the I-type core is disposed on the O-type core, the positioning of both is facilitated using the first recess as a mark.

And noise is further reduced.

And since an O-type core and an I-type core do not contact directly, noise can be reduced more. In addition, the dimension of the I-type core in the same plane can be designed irrespective of the dimension of the first recess in the plane perpendicular to the extending direction of the I-type core.

According to the second aspect of the present invention, even if the dimension of the I-type core in the same plane is larger than the dimension of the first recess in the plane perpendicular to the extending direction of the I-type core, the buffer member can be stabilized. Can be held.

According to the third invention, the deviation of the I-type core can be avoided or suppressed.

According to the fourth invention, noise can be reduced while securing a magnetic path.

  Preferred embodiments of the present invention will be described below with reference to the drawings. In the following drawings including FIG. 1, only elements related to the present invention are shown.

<Outline configuration>
FIG. 1 is a longitudinal sectional view illustrating a reactor 100 according to an embodiment of the present invention, and shows a cross section along the extending direction of the I-type core 20. The reactor 100 includes an O-type core 10, an I-type core 20, and a coil 30. In addition, the white arrow in a figure represents typically the magnetic flux which flows through the reactor 100. FIG.

  FIG. 2 is a perspective view illustrating the O-type core 10. The O-type core 10 is, for example, a substantially rectangular magnetic body having an annular inner wall 14 that exhibits a through-hole 12 that passes through a pair of opposed surfaces, and at least one recess that recedes from the center of the through-hole 12. 16 is formed on the inner wall 14. The distance between the through hole 12 and the outer wall of the O-type core 10 is substantially uniform except for the position of the recess 16. That is, if the outer shape of the O-type core 10 is formed in a substantially rectangular shape, the shape of the through hole 12 is formed in a substantially rectangular shape excluding the position of the recess 16. The O-type core 10 functions as a yoke with respect to the I-type core 20. As shown in FIG. 2, the recess 16 is formed in a substantially rectangular shape when viewed from the extending direction of the I-type core 20.

  The I-type core 20 is, for example, a magnetic material formed in a substantially rectangular shape and substantially the same length as the diameter of the through hole 12, and at least one of the end portions 22 is fitted into the recess 16 to penetrate therethrough. Disposed across the hole 12. At this time, the I-type core 20 is disposed in the through hole 12 of the O-type core 10 that has been heated and expanded in advance, and the positional relationship between the two cores is firmly maintained after the O-type core 10 is cooled. The I-type core 20 functions as a core around which the coil 30 is wound. If the reactor 100 is formed by disposing the I-type core 20 in the through hole 12 of the O-type core 10, compared to the case where the reactor 90 (see FIG. 12) is configured by the E-type core 91 and the I-type core 92. Thus, since the number of boundaries between the cores is changed from three to two, it is possible to reduce places where noise is likely to be generated, thereby reducing noise.

  Here, it is desirable that the I-type core 20 is formed of a higher quality material than the O-type core 10. For example, “high quality” means that a non-oriented material is used for the O-type core 10 and an oriented material is used for the I-type core 20. The non-oriented material is, for example, one obtained by pressurizing iron powder, and the oriented material is, for example, one obtained by heat-treating after iron powder is press-formed. As another specific example, the silicon content of the member forming the I-type core 20 is larger than the silicon content of the member forming the O-type core 10. By adopting such a high-quality material, heat generation in the I-type core 20 disposed at a position where the magnetic flux density becomes high can be suppressed. Therefore, the necessity for adding a cooling device separately is small. In general, such a high-grade material is expensive, so that the cost can be suppressed by making it possible to individually select the material of the O-type core 10 and the material of the I-type core 20.

  FIG. 3 is a cross-sectional perspective view illustrating a component disposed inside the O-type core 10. The coil 30 is made of, for example, a conductive wire, wound around the I-type core 20, and accommodated in the through-hole 12 of the O-type core 10 together with the I-type core 20. Here, by making the thickness Ti in the extending direction of the through hole 12 of the I-type core 20 smaller than the thickness To in the extending direction of the through hole 12 of the O-type core 10 (that is, the extending direction of the recess 16). Since it can suppress that the coil 30 protrudes from the O-type core 10, the reactor 100 can be reduced in size. In particular, it is desirable to use a high-grade material for the I-type core 20 in that the magnetic flux density is less likely to be saturated even if the thickness Ti is reduced.

  An insulating member 50 may be disposed in a region of the through hole 12 excluding the recess 16. Specifically, it is disposed around the inner wall 14 of the through hole 12 adjacent to the coil 30 and the I-type core 20. However, the insulating member 50 is not disposed in the vicinity of the end 22 that fits into the recess 16.

  As the material of the insulating member 50, for example, a high heat-resistant resin such as PPS (Polyphenylene-Sulfide) or LCP (Liquid Crystal Polymer or Liquid Crystal Plastic), glass, or the like is applicable. Note that the material of the buffer member 50 is not necessarily PPS, LCP, or glass. In a normal reactor, the temperature of the core around which the coil is wound rises to about 150 ° C. to 180 ° C. during operation. Therefore, the material of the buffer member 50 only needs to have heat resistance against the temperature.

<Effect of schematic configuration>
As described above, according to the reactor 100 of the present invention, the O-type core 10 in which the concave portion 16 is formed in the inner wall 14 of the through hole 12, the transverse passage extending through the through hole 12, and facing the concave portion 16. Since the I-type core 20 having the arranged end 22 and the coil 30 wound around the I-type core 20 are provided, the material of the I-type core 20 around which the coil 30 is wound, and the I-type The material of the O-type core 10 that functions as the yoke of the core 20 can be individually selected. Therefore, the cost can be suppressed while suppressing the temperature rise in the I-type core 20 and increasing the efficiency of the reactor 100. Further, compared with the case where the E-type core 91 and the I-type core 92 are used, the number of boundaries between the core around which the coil is wound and the core functioning as a yoke is reduced by one, thereby reducing noise. . Further, when the I-type core 20 is disposed on the O-type core 10, the positioning of both is facilitated with the recess 16 as a mark.

<First Configuration Having Buffer Member>
In the above embodiment, the mode in which the I-type core 20 is directly fitted in the recess 16 has been described, but the present invention is not limited to this. Here, a mode in which the buffer member 40a is disposed between the recess 16 and the end 22 of the I-type core 20 will be described with reference to the drawings. In the following description of the embodiment, unless otherwise specified, elements having the same functions as those in the above embodiment are denoted by the same reference numerals and description thereof is omitted.

  FIG. 4 is a partially enlarged view of the reactor to which the first configuration having the buffer member 40a is applied, and shows a region Pa corresponding to the region Px of the reactor 100 shown in FIG. In the following embodiments including this embodiment, the region Py shown in FIG. 1 may have the same configuration.

  The buffer member 40a is formed in a substantially rectangular shape using, for example, a high heat resistant resin such as PPS or LCP, or glass. The buffer member 40a extends in a direction (hereinafter referred to as “width direction”) orthogonal to both the extending direction of the I-type core 20 (hereinafter also referred to as “height direction”) and the penetration direction of the through hole 12. The length Wra is substantially the same as the length Woa along the width direction of the recess 16 and the length Wia along the width direction of the I-type core 20. Further, the length along the height direction of the buffer member 40a is longer than the length along the height direction of the recess 16 (that is, the depth of the recess 16) by the length δ.

<Effect of 1st structure which has a buffer member>
Thus, by providing the buffer member 40a between the recess 16 and the end 22, the noise can be further reduced.

  Moreover, since the length along the height direction of the buffer member 40a is longer than the depth of the concave portion 16 by the length δ, the O-type core 10 and the I-type core 20 are not in direct contact with each other. Therefore, noise can be further reduced. In addition, the dimension of the I-type core 20 in the same plane can be designed regardless of the dimension of the recess 16 in the plane perpendicular to the height direction.

<Second Configuration Having Buffer Member>
Since the O-type core 10 and the I-type core 20 can be individually designed, the length Wia along the width direction of the I-type core 20 may be longer than the length Wo along the width direction of the recess 16. In the second configuration, such a design is described.

  FIG. 5 is a partial enlarged view of the reactor to which the second configuration having the buffer member 40b is applied, and shows a region Pb corresponding to the region Px of the reactor 100 shown in FIG. The buffer member 40b has a fitting body 42b and a holding body 44b.

  The fitting body 42 b is formed in substantially the same shape as the portion of the inner wall 14 of the through hole 12 that retreats from the center of the through hole 12 and fits into the recess 16. The holding body 44b is formed on the opposite side of the fitting body 42b, and the cross-sectional area in the plane perpendicular to the height direction of the holding body 44b is larger than the cross-sectional area in the same surface of the fitting body 42b. The holding body 44 b holds the I-type core 20. In other words, the buffer member 40b is formed in a substantially step shape, and a portion corresponding to the upper stage of the pyramid is fitted into the recess 16 as the fitting body 42b, and a portion corresponding to the lower stage of the pyramid is I as the holding body 44b. The mold core 20 is held.

  As a result, as shown in FIG. 5, the length Wib along the width direction of the I-type core 20 can be expanded to about the length Wrb along the same direction of the holding body 44b. That is, the cross-sectional area in the plane perpendicular to the height direction of the I-type core 20 can be expanded to the cross-sectional area in the same plane of the holding body 44b.

<Effect of the second configuration having a buffer member>
Thus, the buffer member 40b has the fitting body 42b that fits into the recess 16, and the holding body 44b that holds the I-type core 20 on the opposite side of the fitting body 42b, and in a plane perpendicular to the height direction. By making the cross-sectional area of the holding body 44b larger than the cross-sectional area of the fitting body 42b in the same plane, the dimension in the same plane of the I-type core 20 can be made larger than the dimension of the recess 16 in the same plane. Even if it is expanded, the buffer member 40b can be stably held.

<Third configuration having a buffer member>
FIG. 6 is a partially enlarged view of the reactor to which the third configuration having the buffer member 40c is applied, and shows a region Pc corresponding to the region Px of the reactor 100 shown in FIG. The I-type core 20 has a recess 24c at a portion in contact with the buffer member 40c.

  The length Wrc along the width direction of the buffer member 40c is formed to be substantially the same length as the length Wo along the width direction of the recess 16 and the length along the height direction of the buffer member 40c is The length δ is longer than the length along the height direction.

  Further, the length Wic along the width direction of the I-type core 20 is formed to be longer than the length Wrc along the width direction of the buffer member 40c. The I-type core 20 has a recess 24c at its end 22 that has a width substantially the same as the length Wo along the width direction of the buffer member 40c and a depth shallower than the length δ. Has been. The buffer member 40c is fitted into the recess 24c.

  That is, one end of the buffer member 40c is fitted into the recess 16 and the other end is fitted into the recess 24c.

<Effect of the third configuration having a buffer member>
As described above, the I-type core 20 has the concave portion 24c at the portion (end portion 22) in contact with the buffer member 40c, and the buffer member 40c is fitted with the concave portion 24c. Deviation with respect to the direction perpendicular to can be avoided or suppressed.

<Fourth Configuration Having Buffer Member>
7 (a) and 7 (b) are partial enlarged views of the reactor to which the second configuration having the buffer members 40d and 40e, respectively, are applied. Regions Pd and Pd corresponding to the region Px of the reactor 100 shown in FIG. Pe is shown. The I-type core 20 has convex portions 26d and 26e at portions in contact with the buffer members 40d and 40e.

  Similarly to the second configuration having the buffer member 40b, the buffer members 40d and 40e have fitting bodies 42d and 42e and holding bodies 44d and 44e. And the recessed parts 46d and 46e are provided in the surface where the holding bodies 44d and 44e contact the I-type core 20. As shown in FIG. The lengths of the recesses 46 d and 46 e along the width direction are shorter than the length Wo along the width direction of the recess 16 and shorter than the lengths Wid and Wie along the width direction of the I-type core 20.

  Further, the end 22 of the I-type core 20 has a width that is substantially the same as the length along the width direction of the recesses 46d and 46e, and the height is substantially the same as the depth of the recesses 46d and 46e. Convex portions 26d and 26e are provided.

  That is, the buffer members 40d and 40e are fitted to the recesses 16 with the fitting bodies 42d and 42e having the same function as the fitting body 42b shown in the second configuration having the buffer member 40b, and are provided on the holding bodies 44d and 44e. The recessed portions 46d and 46e thus formed are fitted with the protruding portions 26d and 26e of the I-type core 20. In addition, the shape of the convex portions 26d and 26e and the concave portions 46d and 46e fitted to the convex portions 26d and 46e is, for example, as shown in a region Pd in FIG. Alternatively, as shown in a region Pe in FIG. 7B, the shape of the convex portion 26e and the concave portion 46e may be substantially triangular in cross section.

<Effect of 4th structure which has a buffer member>
As described above, the I-type core 20 has the convex portions 26d and 26e at the portions in contact with the buffer members 40d and 40e, and the buffer members 40d and 40e are fitted with the convex portions 26d and 26e, so that the magnetic path is secured. Noise can be reduced.

  Further, since the buffer members 40d and 40e have recesses 46d and 46e at the portions in contact with the I-type core 20, and the I-type core 20 is fitted with the recesses 46d and 46e, the I-type core 20 is displaced, particularly in the height direction. Deviation with respect to the direction perpendicular to can be avoided or suppressed.

<Fifth configuration having a buffer member>
FIG. 8 is a partially enlarged view of the reactor to which the second configuration having the buffer member is applied, and shows a region Pf corresponding to the region Px of the reactor 100 shown in FIG. In the fifth configuration having the buffer member 40f, an example in which the end 22 of the I-type core 20 is disposed in the recess 16 is illustrated. The length along the height direction of the buffer member 40f employed in place of the buffer members 40a to 40e employed in the first to fourth configurations is shorter than the depth of the recess 16 by the length δ.

  The buffer member 40f is formed in a substantially rectangular shape as shown in the first configuration having the buffer member, and the length Wrf in the width direction is substantially equal to the length Wo along the width direction of the recess 16. It is the same. The end 22 of the I-type core 20 is held in the recess 16 in contact with the buffer member 40f. In this configuration, the length Wif along the width direction of the end portion 22 is shorter than the length Wo along the width direction of the recess 16.

<Effect of 5th structure which has a buffer member>
Thus, since the height of the buffer member 40f is shorter than the height (depth) of the recess 16, noise can be reduced while securing a magnetic path. In addition, the dimension of the I-type core 20 in the same plane can be designed regardless of the dimension of the recess 16 in the plane perpendicular to the extending direction of the I-type core 20.

<6th structure which has a buffer member>
FIG. 9 is a partially enlarged view of the reactor to which the second configuration having the buffer member is applied, and shows a region Pg corresponding to the region Px of the reactor 100 shown in FIG. In the sixth configuration having the buffer member 40g, the buffer member 40g has a recess 46g at a portion facing the end 22 of the I-type core 20.

  The recess 46g is formed so that the length Whg along the width direction is substantially the same as the length Wig along the width direction of the I-type core 20, and is in contact with the entire end portion 22. That is, when the surface of the end portion 22 on the buffer member 40g side extends, for example, in a plane having the rotation axis Q as a normal line, the bottom surface 47g of the recess 46g also extends in the same plane. Thereby, the I-type core 20 and the buffer member 40g, more specifically, the I-type core 20, the concave portion 46g, and the bottom surface 47g can be fitted and the mutual positional relationship can be maintained tightly.

<Effect of 6th structure which has a buffer member>
Thus, since the buffer member 40g has the recessed part 46g in the site | part which contact | connects the I-type core 20 (end part 22), and the I-type core 20 (end part 22), the recessed part 46g, and the bottom face 47g fit, Deviation of the I-type core 20 can be avoided or suppressed.

<7th structure which has a buffer member>
FIG. 10 is a partial enlarged view of the reactor to which the second configuration having the buffer member is applied, and shows regions Ph and Pi corresponding to the region Px of the reactor 100 shown in FIG. In the seventh configuration having the buffer members 40h and 40i, the I-type core 20 has the convex portions 26h and 26i at the portions in contact with the buffer members 40h and 40i.

  The buffer members 40h and 40i have shapes in which the holding bodies 44d and 44e of the buffer members 40d and 40e shown in the fourth configuration having the buffer members 40d and 40e are retracted into the fitting bodies 42d and 42e. Specifically, the buffer members 40 h and 40 i are formed so as to fill substantially the entire recess 16, and the recesses 46 h and 46 i are provided on the surface facing the end 22 of the I-type core 20. The lengths of the recesses 46 h and 46 i along the width direction are shorter than the length Wo along the width direction of the recess 16 and shorter than the lengths Wih and Wii along the width direction of the I-type core 20.

  Further, the end 22 of the I-type core 20 has a width that is substantially the same as the length along the width direction of the recesses 46h and 46i, and the height is substantially the same as the depth of the recesses 46h and 46i. Convex portions 26h and 26i are provided.

  In other words, the buffer members 40 h and 40 i are fitted to the concave portion 16, while the concave portions 46 h and 46 i are fitted to the convex portions 26 h and 26 i of the I-type core 20. Note that the shapes of the convex portions 26h and 26i and the concave portions 46h and 46i fitted to the convex portions 26h and 46i are, for example, substantially rectangular in the sectional view as shown in the region Ph of FIG. Alternatively, as shown in a region Pi in FIG. 10B, the shape of the convex portion 26i and the concave portion 46i may be a substantially triangular shape in cross-sectional view.

<Effect of 7th structure which has a buffer member>
Thus, since the I-type core 20 has the convex portions 26h and 26i at the portions contacting the buffer members 40h and 40i and the buffer members 40h and 40i are fitted with the convex portions 26h and 26i, the noise is secured while securing the magnetic path. Can be reduced.

<Modification>
The preferred embodiment of the present invention has been described above, but the present invention is not limited to this, and may be a combination of the first to seventh configurations.

  FIG. 11 is a perspective view illustrating an O-type core 10z according to a modification. Unlike the O-type core 10 described above, the recess 16z of the O-type core 10z may be formed on a part of the through-hole 12 in the through-hole 12 on the inner wall 14 as shown in FIG. It may not be formed.

  Normally, when the reactor 100 is manufactured, a structure as shown in FIG. 3 (an assembly of the I-type core 20 and the coil 30) is inserted into the O-type core 10 (see FIG. 2). 2, when the recess 16 is formed over the entire penetration direction of the through hole 12, the component inserted from one side of the through hole 12 in the manufacturing process is dropped to the other side. There is a possibility that.

  Accordingly, it is desirable that the recess 16z is formed on the inner wall 14 in a part of the through hole 12 in the penetrating direction so as to prevent the component from dropping out in the manufacturing process. However, in order not to hinder the flow of magnetic flux of the reactor 100 (see FIG. 1), it is desirable that the portion where the through hole 12 is not formed is thin enough to prevent dropping. Further, for convenience of insertion, it is desirable that either one of the end portions of the recess 16z in the penetration direction is vacant.

It is a longitudinal cross-sectional view which illustrates the reactor which concerns on embodiment of this invention. It is a perspective view which illustrates an O-type core. It is a cross-sectional perspective view which illustrates the structure arrange | positioned inside an O-type core. It is the elements on larger scale of the reactor to which the 1st composition which has a buffer member is applied. It is the elements on larger scale of the reactor to which the 2nd composition which has a buffer member is applied. It is the elements on larger scale of the reactor to which the 3rd composition which has a buffer member is applied. It is the elements on larger scale of the reactor to which the 4th composition which has a buffer member is applied. It is the elements on larger scale of the reactor to which the 5th composition which has a buffer member is applied. It is the elements on larger scale of the reactor to which the 6th structure which has a buffer member is applied. It is the elements on larger scale of the reactor to which the 7th composition which has a buffer member is applied. FIG. 9 is a perspective view illustrating an O-type core according to a modification. It is a longitudinal cross-sectional view which illustrates the conventional reactor.

Explanation of symbols

100 Reactor 10 O-type Core 12 Through Hole 14 Inner Wall 16 Recess
20 I-type core 22 End 24c Recess (second recess)
26d, 26e, 26h, 26i Convex part 30 Coil 40a-40i Buffer member 42b, 42d, 42e Fitting body 44b, 44d, 44e Holding body 46d, 46e, 46h, 46i Concave part (third concave part)
50 Insulating material

Claims (4)

An O-shaped core (10) having an annular inner wall (14) exhibiting a through-hole (12) and having at least one first recess (16) retreating from the center of the through-hole formed in the inner wall;
An I-shaped core (20) having an end (22) extending across the through hole and disposed opposite the first recess;
A coil (30) wound around the I-shaped core ;
A buffer member (40a-40i) disposed between the first recess (16) and the end (22) ;
The length of the buffer member (40a to 40e) along the extending direction of the I-shaped core (20) is longer than the length of the first recess (16) along the extending direction of the reactor (100 ). A reactor (100) according to claim 1,
The buffer member (40b-40e)
A fitting body (42b, 42d, 42e) fitted into the first recess (16);
Holding bodies (44b, 44d, 44e) for holding the I-type core (20) on the opposite side of the fitting body;
Have
A reactor in which a cross-sectional area of the holding body in a plane perpendicular to the extending direction of the I-type core is larger than a cross-sectional area of the fitting body in the plane . A reactor (100) according to claim 1 or claim 2, wherein
The I-type core (20) has a second recess (24c) at a portion in contact with the buffer member,
The said buffer member (40c) is a reactor fitted with the said 2nd recessed part . A reactor (100) according to claim 1 or claim 2 , wherein
The I-type core (20) has convex portions (26d, 26e) at portions contacting the buffer members (40d, 40e),
The said buffer member is a reactor fitted with the said convex part .

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