JP2019192867A - Reactor device - Google Patents

Abstract

To provide a reactor device capable of easily winding a coil around an entire core and uniformly distributing a flux density.SOLUTION: A reactor device comprises: coil parts 103 and 104; two semi-circular core parts 101A and 101B in which parts inserted into the coil parts 103 and 104 are formed by the same curvature arc state regions and form similar shapes each other; and two I core parts 102A and 102B distributed so as to guide magnetic fluxes flowing through the toroidal-like core parts 101A and 101B to opposite positions in a radial direction while being sandwiched between end surfaces opposite to each other of these two semi-circular core parts 101A and 101B when forming the toroidal-like core part by combining these two semi-circular core parts 101A and B. The two I core parts 102A and 102B are distributed at positions opposite to each other across a gap.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a reactor device mounted on, for example, an electric vehicle or a hybrid vehicle, and more particularly to a reactor device in which a part of a core constituting a magnetic path is inserted in a coil.

  Conventionally, an in-vehicle magnetically coupled reactor has an E core shape (U core + I core), and a U core shape reactor device based on the E core shape is also known. For example, as shown in Patent Document 1 below, in a pair of U cores having three linear portions and a corner portion between them, both leg portions are butted together so that two I cores are sandwiched therebetween, and the entire ring is The shape is known. In such a core shape, corners are formed at the four corners of the ring shape.

JP 2016-66720 A

  In this way, the core shape having the corners makes it easy to wind the coil in the straight part, but it is difficult to wind the coil around the corners of the core, and the winding region of the core is not uniform. . Further, since the corners are present, magnetic saturation is partially performed (the magnetic flux density is uneven), so that an extra cross-sectional area is required as a core.

  The present invention has been made in view of the above circumstances, and provides a reactor device that can easily wind a coil around the entire core and can uniformly distribute a magnetic flux density as compared with the prior art. Objective.

In order to solve the above problems, a reactor device according to the present invention is:
A coil section;
Two semicircular core parts having the same shape as each other, wherein the part inserted into the coil part is formed of an arcuate region having the same curvature;
A sub-core portion disposed so as to guide a magnetic flux flowing in the toroidal core portion to a radially opposed position when the two semicircular core portions are combined to form a toroidal core portion; It is characterized by having.

In addition, when the sub-core portion is combined with the two semicircular core portions to form a toroidal core portion, the two plates are respectively sandwiched between opposing portions of the end faces of the two semicircular core portions. With a core-shaped part,
It is preferable that the two plate-shaped core portions are arranged to face each other with a gap interposed therebetween.

  The “toroidal core portion” is obtained by dividing an annular core whose cross section is a perfect circle into half and re-combining them with the original shape, or re-combining them with the original shape. In this case, it refers to a core part in which a sub-core part composed of a plate-like core part or the like is sandwiched between opposing parts of the legs of the semicircular core part. Furthermore, a mode in which the abutting part is partially linearly shaped or has an increased curvature of an arc so that the leg part of the semicircular core part easily abuts on a sub-core part made of a plate-like core part or the like is included. .

  Further, the semicircular core portion is formed by stacking a plurality of semicircular unit cores having the same shape, and the upper and lower surfaces of the semicircular unit cores in the stacking direction are planar. preferable.

  The coil portion is preferably formed by edgewise winding a rectangular wire.

Further, the coil portion may be provided with a small-diameter winding portion having a first predetermined number of turns and a large-diameter winding portion having a second predetermined number of turns.
Here, the “first predetermined number of turns” and the “second predetermined number of turns” can each be an arbitrary number of 1 or more, and the predetermined number of turns at each position is constant or not constant. Good.
Or it is preferable to comprise so that the envelope of the at least outer peripheral part of the said coil part may draw a circular arc.

In the conventional reactor device, an E core or a U core having a corner portion is used as the core portion. However, in the reactor device of the present invention, the core portion inserted into the coil portion has an arc-shaped region having the same curvature. Consists of two semicircular core parts having the same shape as each other, and since there are no corners in the entire area of the core, it is easy to wind the coil, and the core winding area is uniform. Can be arranged.
In addition, since there is no corner, it is easy to make the magnetic flux density uniform, and magnetic saturation can proceed uniformly and partial magnetic saturation can be suppressed. For this reason, an extra cross-sectional area is unnecessary as a core, and it can be set as a compact and efficient reactor apparatus.

  Further, when the core portion has the shape as described above, it is difficult to form a multi-gap configuration, but two cross-section I-shaped plate core portions that are respectively sandwiched between opposing portions of the legs of the semicircular core portion. Since the gap is provided between them, the gap can be provided in the central portion of the reactor device, so that it is not always necessary to have a multiple gap configuration.

It is a perspective view which shows the reactor apparatus which concerns on embodiment of this invention. It is a top view of the reactor apparatus shown in FIG. It is a perspective view which shows the core part of the reactor apparatus which concerns on embodiment of this invention. It is a top view of the core part of the reactor apparatus shown in FIG. It is a perspective view which shows the reactor apparatus which concerns on the modification of embodiment of this invention. It is a top view of the reactor apparatus shown in FIG. It is the schematic which shows the reactor apparatus which concerns on the other modification of embodiment of this invention.

  Hereinafter, a reactor device according to an embodiment of the present invention will be described with reference to FIGS.

<Main configuration of reactor device>
As shown in FIGS. 1 and 2, the main part of the reactor device 100 according to the embodiment of the present invention includes semicircular core parts 101 </ b> A, B and leg parts (left and right leg parts 111 </ b> A, B and 112 </ b> A, B). Are arranged so that their tips are opposed to each other, and a toroidal core portion is formed together.
Between these opposing leg portions (left and right leg portions 111A, B and 112A, B), plate-like I core portions 102A, B are respectively sandwiched in the thickness direction. The pair of plate-shaped I core portions 102 </ b> A and 102 </ b> B are arranged so as to face each other with a gap 105 at the center of the toroidal core portion. As a result, the core portion is shaped such that the I core portions 102A and 102B function as middle legs, and a pair of E-type cores are disposed opposite to each other as a whole.

Around the semicircular core portions 101A and 101B, coil portions 103 and 104 formed by edgewise winding a rectangular wire are disposed. That is, the coil part 103 is arranged so as to surround the most part of the semicircular core part 101A, while the coil part 104 is arranged so as to surround the most part of the semicircular core part 101B.
Thus, in the reactor apparatus of this embodiment, since the core part is comprised so that it may become a toroidal core shape, each winding part of the coil parts 103 and 104 arrange | positioned around this core part is equal. The magnetic characteristics can be improved.

  Further, since there are no corners, it is possible to avoid the disadvantage that magnetic saturation proceeds uniformly and only a part of the magnetic saturation is magnetically saturated.

Each element described above will be described in more detail.
<Semicircular core part>
The semicircular core parts 101A and B described above have the same shape as that obtained by dividing a perfect circular toroidal core into two so as to be symmetrical with each other.
However, the leg portions 111A, B, 112A, B of the opposed semicircular core portions 101A, B are plate-like I core portions sandwiched between the opposed portions of the leg portions 111A, B, 112A, B. A part of the shape is linear or close to a straight line so that they can be in good contact with each other and easily bonded to each other. However, the portions of the legs 111A, B, 112A, and B that are linear or close to a straight line as described above are set to a short distance limited to the vicinity of the region that contacts the I-core portions 102A and B. In the region where the coils 103 and 104 are wound, the arc shape has the same curvature.

  The semicircular core portions 101A, B are formed by overlapping two semicircular unit cores 101A1, A2, 101B1, B2 having substantially the same shape, thereby simplifying the manufacturing process. However, the amount of magnetic flux interlinking can be increased. Of course, the semi-circular unit core may be formed in one stage, or may be stacked in three or more stages.

<I core part>
As described above, the I core portions 102A and 102B have a flat shape as shown in FIG. 3, and the legs 111A, B, 112A, and B of the semicircular core portions 101A and B are formed in the thickness direction. In this state, the side surfaces of the pair of I core portions 102 </ b> A and 102 </ b> B are arranged so as to face each other with a gap 105 therebetween. Further, the I core portions 102A, B and the semicircular core portions 101A, B legs 111A, B, 112A, B are directly bonded by an adhesive, but may be bonded to each other via a spacer. .

The height of the I core portions 102A, B in the vertical direction (the axial direction of the toroidal core portion) is formed to be greater than the height of the toroidal core portions (semicircular core portions) 101A, B. In addition, when the entire core portion is regarded as a shape in which the E-type core is abutted, the I core portions 102A and 102B can be regarded as the middle leg portions of the E-type cores.
Since the corners of the shoulders 102C and D of the I cores 102A and 102B protruding from the surfaces of the semicircular cores 101A and B do not easily flow magnetic flux, the corners of the shoulders 102C and D are removed. Chamfering is applied to make the entire core compact.
The outer peripheral surfaces of the semicircular core portions 101A and B are formed to be flush with the outer surfaces of the I core portions 102A and B.

<Constituent material of core part>
In the present embodiment, the dust core is compacted as the constituent material of the semicircular core portions 101A, B and the I core portions 102A, B, but a laminated core in which ferrite or silicon steel is laminated is used. it can. The semicircular core portions 101A, B and the I core portions 102A, B may be made of the same material or different materials.

  In addition, the gap 105 provided between the side surfaces of the pair of I core portions 102A and 102B may be an air gap or a gap provided with a spacer.

<Coil part>
The coil portions 103 and 104 are formed by winding a rectangular wire by edgewise winding. A flat wire is a belt-like flat conductor as shown in FIG. 1 and the like, and for example, a wire having a thickness of 0.5 to 6.0 mm and a width of 1.0 to 16.0 mm is generally used. Of course, other cross-sectional shapes such as a round wire can be used.
At both ends of the coil portion 103, one end 103A is located on the inner periphery, and the other end 103B is located on the outer periphery. Also in the coil part 104, one end part 104 </ b> A is located on the inner peripheral part and the other end part 104 </ b> B is located on the outer peripheral part. However, the present invention is not limited to the above wiring method, and any winding direction and current energization direction can be employed as long as the directions of magnetic fluxes generated from the coils cancel each other.

The coil portions 103 and 104 are uniformly wound around the semicircular core portions 101A and B (except in the vicinity of the contact portions with the I cores 101A and B). Since the regions of the semicircular core portions 101A, B around which the coil portions 103, 104 are wound are arcs having the same curvature, the coil portions 103, 104 can be easily and uniformly wound.
Since the two coil portions 103 and 104 are wound in such a direction that the generated DC magnetic fluxes cancel each other, the rectangular wires are wound in the opposite direction, and both the coil portions 103 and 104 are energized. The direction of the current may be the same, or the rectangular wires may be wound in the same direction, and the direction of the current supplied to both coil portions 103 and 104 may be reversed.

  In the process of assembling the semicircular core portions 101A, B and the coil portions 103, 104, the semicircular core portions 101A, B and the I core portions 102A, B are formed in a cylindrical shape in the previous step of bonding. The semicircular core portions 101A and 101B are inserted into the coil portions 103 and 104, and the coil portions 103 and 104 are wound around the semicircular core portions 101A and 101B.

<Modification>
5 and 6 are a perspective view and a plan view showing a reactor device 200 according to a modification of the embodiment of the present invention.
In this modification, there are many members that are common (corresponding) to those of the above-described embodiment. Therefore, for such members that are common (corresponding), the member numbering in the above embodiment is added with 100. The members are numbered in the present embodiment, and detailed description thereof is omitted.
That is, the reactor device 200 according to this modification is configured to be similar to the reactor device 100 of the above embodiment, but the shape of a part of the coil portions 203 and 204 is different from that of the reactor device 100 of the above embodiment. Is different.

The winding portions of the coil portions 203 and 204 are basically small-diameter winding portions 203C and 204C. However, in place of (or in addition to) the small-diameter winding portions 203C and 204C every five turns, Winding portions 203D and 204D having a diameter are provided.
However, the outer peripheral surfaces of the large-diameter winding portions 203D and 204D are aligned with the outer peripheral surfaces of the small-diameter winding portions 203C and 204C.
As described above, when the large-diameter winding portions 203D and 204D are provided, the inner peripheral portion thereof is positioned inside the inner peripheral portion of the small-diameter winding portions 203C and 204C, and the small-diameter winding portion is provided. Since it is possible not to overlap the inner peripheral portions of 203C and 204C, it is possible to increase the number of turns while keeping the external dimensions of the product (however, the height dimension becomes large). This is because when the thickness of the electric wire is increased, the number of turns of the small-diameter winding parts 203C and 204C decreases, but the addition of the large-diameter winding parts 203D and 204D reduces the number of turns of the coil. It is possible to compensate, and copper loss can be kept low.

Moreover, in the reactor apparatus 100 of the said embodiment, as FIG. 2 also shows clearly, the big space where the coil parts 103 and 104 are not arranged on the inner peripheral side has arisen, but in the reactor apparatus 200 which concerns on this modification, As is clear from FIG. 6, the large-diameter winding portions 203D and 204D enter the space portion so that the space is effectively used.
Therefore, reactor device 200 does not increase in size in the radial direction.
However, the upper surfaces of the large-diameter winding portions 203D and 204D are configured to protrude upward from the upper surfaces of the small-diameter winding portions 203C and 204C.

FIG. 7 is a conceptual diagram showing a reactor device 300 according to another modification of the embodiment of the present invention.
Although the basic function of the reactor device 300 of this modification is the same as that of the said embodiment, it replaces with I core part 102A, B in embodiment mentioned above, and the cylindrical rod core 302 is provided. That is, in a state where the pair of semicircular core portions 301A and B are inserted into the coil portions 303 and 304 (representing the state of being wound by cross-hatching without drawing the winding state), The end faces of the pair of semicircular core portions 310A and 310B are directly bonded without sandwiching the I core portion, and a cylindrical rod core is provided at the center of the toroidal core formed by bonding. 302 is arranged.

In this case, the magnetic flux is formed so as to flow from one boundary portion 310A to the other boundary portion 310B through the rod core 302, or vice versa.
Also in such a modification example, since the toroidal core is formed by the pair of semicircular core portions 301A and B, the operation and effect are the same as those of the above embodiment.

The reactor device of the present invention is not limited to the shape of the above embodiment and the above modified example, and various other modes can be modified.
For example, the cross-sectional shape of the semicircular core portion does not have to be a rectangle, and may be another shape such as a circle.

The shape of the I core portion is not limited to that of the above embodiment, and can be changed to other various shapes.
In the above, one coil part is wound around each semicircular core, but two or more coil parts may be provided in each semicircular core.
The cross-sectional shape of the rod-shaped core according to the other modification is not necessarily a circle, and may be a rectangle or other shapes.

100, 200, 300 Reactor device 101A, B, 201A, B, 301A, B Semicircular core part 101A1, 101A2, 101B1, 101B2 Semicircular unit core 102A, B, 202A, BI core part 102C, D Shoulder part 103, 104, 203, 204, 303, 304 Coil part 103A, 104A, 203A, 204A One end part 103B, 104B, 203B, 204B The other end part 203C, 204C Small diameter part 203D, 204D Large diameter part 302 Bar core 310A, B Boundary Part

Claims (6)

A coil section;
Two semicircular core parts having the same shape as each other, wherein the part inserted into the coil part is formed of an arcuate region having the same curvature;
A sub-core portion disposed so as to guide a magnetic flux flowing in the toroidal core portion to a radially opposed position when the two semicircular core portions are combined to form a toroidal core portion; A reactor device characterized by comprising. When the sub-core part combines the two semicircular core parts to form a toroidal core part, two plate-like cores that are respectively sandwiched between opposing portions of the end faces of the two semicircular core parts Part
The reactor device according to claim 1, wherein the two plate-shaped core portions are disposed to face each other via a gap.   The semicircular core portion is formed by stacking a plurality of semicircular unit cores having the same shape, and the upper and lower surfaces in the stacking direction of the semicircular unit cores are planar. The reactor device according to claim 1 or 2.   The reactor device according to claim 1, wherein the coil portion is formed by edgewise winding a rectangular wire.   5. The reactor device according to claim 4, wherein the coil portion includes a small-diameter winding portion having a first predetermined number of turns and a large-diameter winding portion having a second predetermined number of turns.   The reactor device according to claim 5, wherein an envelope of at least an outer peripheral portion of the coil portion draws an arc.

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