Amorphous transformer

Abstract

To improve reliability of an amorphous transformer.SOLUTION: An amorphous transformer includes an insulation member having a flat part corresponding to a flat surface of a coil and a folding part arranged between an inner peripheral surface of the coil and an outer peripheral surface of an amorphous core. The folding part of the insulation member has a structure in which a length at a corner is inhibited from being shorter than other parts of a side.SELECTED DRAWING: Figure 1G

Description

Technical Field

[0001] The present invention relates to an amorphous transformer.

Background Art

[0002] As a transformer with high power conversion efficiency and excellent environmental performance, an amorphous transformer using a laminate of amorphous thin films for the core is known. As an example thereof, Patent Document 1 is known.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In Patent Document 1, when inserting an amorphous core into a coil, in order to prevent the intrusion of amorphous fragments into the coil, it is disclosed that a second insulating member 3 is installed at the coil end before inserting the amorphous core. It is considered that a predetermined object is achieved even by the method described in Patent Document 1. However, the inventors of the present application considered that it is more desirable to further improve the certainty of preventing the intrusion of fragments in order to further improve the reliability of the amorphous transformer.

[0005] Therefore, an object of the present invention is to provide an amorphous transformer that can more effectively prevent the intrusion of amorphous fragments into the coil.

Means for Solving the Problems

[0006] An example of the means for solving the above problems is as follows.

[0007] In an amorphous transformer having an insulating member in which a flat portion corresponding to the plane of the coil is provided and a folded portion is disposed between the inner peripheral surface of the coil and the outer peripheral surface of the amorphous core, the folded portion of the insulating member has a structure that avoids the length at the corner portion from being shorter than the other portions of the side.

Effect of the Invention

[0008] According to the amorphous transformer of the present invention, the intrusion of amorphous fragments into the coil can be more reliably suppressed, so that the reliability of the amorphous transformer can be improved.

[0009] Further means and further effects of the present invention will become apparent throughout the following full text of the specification.

Brief Description of the Drawings

[0010]

Figure 1A

Figure 1B

Figure 1C

Figure 1D

Figure 1E

Figure 1F

Figure 1G

Figure 1H

Figure 1I

Figure 1J

Figure 1K

Figure 1L

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6A

Figure 6B

Figure 6C

Figure 6D

Figure 6E

Figure 6F

Figure 7

Figure 8

Mode for Carrying Out the Invention

[0011] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

Embodiment

[0012] FIG. 1A is an explanatory diagram showing the initial shape of the insulating member used in one embodiment of the present invention. With respect to the insulating member base 1, as a primary process, it is cut along the cutting line 2 and folded along the folding line 3. Since the insulating member base is required to be an insulating material that can be folded, kraft paper or the like can be used. As an example, it is kraft paper with a thickness of about 0.25 mm.

[0013] FIG. 1B is an explanatory diagram showing an image of the shape after the primary process has been performed on the insulating member base 1. The insulating member base 1 is divided into a total of four cut members, 11a, 12a, 13a, and 14a. Each of the cut members has 11b, 12b, 13b, and 14b as long-side folding portions. Also, each has 11c, 12c, 13c, and 14c as short-side folding portions.

[0014] FIG. 1C is an explanatory diagram for explaining the shape of 11a. The X direction and Y direction are set, and it is a diagram for facilitating the understanding of the three-dimensional shape.

[0015] FIG. 1D is a perspective view seen from the X direction of FIG. 1C. With respect to the insulating member base 1, it is bent at the folding portion, and the long-side folding portion 11b is formed.

[0016] FIG. 1E is a perspective view seen from the Y direction of FIG. 1C. With respect to the insulating member base 1, it is bent at the folding portion, and the short-side folding portion 11c is formed.

[0017] The same process is performed on a total of four cut members, 11a, 12a, 13a, and 14a.

[0018] FIG. 1F is an explanatory diagram showing the state of the secondary process of bringing together a total of four members, 11a, 12a, 13a, and 14a, toward the center as the secondary process. As this secondary process, finally, 11a, 12a, 13a, and 14a are brought together toward the center so that they overlap each other.

[0019] Figure 1G is an explanatory diagram showing the shape after secondary processing. 11a and 12a are overlapping parts and have 11a + 12a. Similarly, as overlapping parts between members, there will be a total of four overlapping parts: 11a + 14a, 13a + 14a, and 12a + 13.

[0020] To facilitate understanding of the shape, the X - direction and Y - direction are set in Figure 1G.

[0021] Figure 1H is an explanatory diagram showing the three - dimensional structure around the A - A line of Figure 1G. It has a region of 11a alone on the left side and a region of 12a alone on the right side. In the central part, a region where 11a and 12a overlap is formed as 11a + 12a.

[0022] At the same time, folding parts 11b and 12b are formed. The characteristic at this time is that as the standing part formed by two folding sides, the corner part is the longest and the shortest part is formed near the center. In other words, it can also be said that a mountain part is formed at the corner and a valley part is formed in the center. Also, it can be said that the highest structure or the longest structure is formed at the corner. Furthermore, it can be said that it is a structure that avoids the length or height of the corner part being lower or shorter than other parts of that side.

[0023] Figure 1I is an explanatory diagram showing the three - dimensional structure around the B - B line of Figure 1G. The way of looking at and thinking about the shape is the same as in the case of Figure 1H.

[0024] Figure 1J is an explanatory diagram showing the shape after secondary processing for understanding the situation of overlapping Figure 1H and Figure 1I, and it is a three - dimensional view of the upper left corner part of Figure 1G. As is clear from the figure, at the corner part, it is configured such that the insulating member becomes the longest or the highest by 14c and 12b.

[0025] Figure 1K is a diagram showing that as the third - stage processing, an insulating tape 5 is attached to Figure 1J. Thereby, 14c and 12b are integrated and the insulating structure is completed.

[0026] Similarly, for other corners, with the same structure and processing, a structure is adopted to avoid the corners not being the lowest parts throughout the entire circumference, that is, to avoid the corners being shorter than other parts of the circumference.

[0027] Here, let's look at the structure disclosed in Patent Document 1. For example, FIG. 6 discloses a structure in which the second insulating member is bent. The concept of bending itself is similar to the description in this embodiment. The difference lies in the way of bending and the part of the structure realized by bending.

[0028] In the structure disclosed in Patent Document 1, as disclosed in FIG. 6 and other figures, it has a structure where the folded part at the corner is the shortest. So to speak, it is a structure where the corner becomes a valley part.

[0029] On the other hand, in view of the object of the present invention again, it is to suppress the intrusion of amorphous fragments into the coil when inserting the amorphous core into the coil. At this time, as a result of examining where the part where amorphous fragments are most likely to occur from the amorphous core when inserting the amorphous core into the coil, the present inventors have found that it is the corner. [[ID=J14]]

[0030] Because it is an amorphous core composed of the lamination of amorphous thin films, at the corner, the end of the outermost thin film of the amorphous thin film faces the corner of the coil. Therefore, when an external force such as contact is applied, structural damage and the shedding of fragments are likely to occur, so to speak, it becomes the weakest point.

[0031] For this reason, the present inventors have found that in order to further improve the certainty of preventing the intrusion of fragments and further improve the reliability of the amorphous transformer, expanding the protection range at the corner is the most structurally optimal countermeasure.

[0032] Therefore, in the present invention, with respect to the structure in which the insulating member becomes a valley part at the corner, which is the structure disclosed in Patent Document 1 as a result, in order to actively protect the corner, it is intended to have a structure where the corner does not become a valley part.

[0033] In this embodiment, as an example, the insulating member is at the corner. The shortest length among its surroundings is avoided. Thereby, the protection at the corner can be strengthened, and the dropping of amorphous fragments and its influence can be reduced. The effect of the present invention has achieved a remarkable difference at this stage compared with Patent Document 1. Therefore, at this stage, the present invention claims its technical idea and effect.

[0034] In the case of Patent Document 1, the structure at the corner has no folding part. On the contrary, in the technical idea of the present invention, it can be said that the folding part abuts against the folding parts of other sides at the corner.

[0035] Furthermore, it can also be said that the folding parts are formed over the entire circumference due to the abutment. Thereby, protection and suppression against the dropping of amorphous fragments from the amorphous core can be realized over the entire set.

[0036] At this time, it can also be expressed that the two adjacent folding parts abut orthogonally at the corner. Thereby, the protection of the corner is realized without gaps.

[0037] Furthermore, it is also possible to achieve further improvement in the effect by actively making the insulating member the longest or the highest at the corner.

[0038] Next, as the tertiary processing, in FIG. 1L corresponding to FIG. 1G, the insulating tape 5 is also attached to the overlapping part of the planar insulating member, and the whole is integrated. Thereby, the insulating member 20 is completed.

[0039] FIG. 2 is a plan view showing the state where the insulating member 20 is grounded with respect to the coil 8. The shape is such that the folding part of the insulating member 20 is located inside the inner circumference of the coil 8.

[0040] Figure 3 is a schematic three-dimensional view for explaining the shape or three-dimensional shape in the perpendicular direction of Figure 2. It can be more easily understood that the folded portion 21 of the insulating member 20 is located inside the inner circumference of the coil 8.

[0041] Figure 4 is the same as Figure 3 and is a schematic three-dimensional view for explaining the three-dimensional shape of the other side. It can be more easily understood that the folded portion 22 of the insulating member 20 is located inside the inner circumference of the coil 8. Note that 21 in Figure 3 corresponds to the long-side folded portions such as 11b, 12b, 13b, and 14b in Figure 1, and 22 in Figure 4 corresponds to the short-side folded portions such as 11c, 12c, 13c, and 14c in Figure 1.

[0042] Then, by fixing and securing these folded portions to the coil 8 with an adhesive or the like, the snagging during the insertion of the amorphous core is suppressed, and the generation and dropping of more amorphous fragments are suppressed.

[0043] Figure 5 is a figure in which the positional relationship of the amorphous core 9 is added to Figure 2. It is an explanatory diagram of the insulating plane structure around the insulating member 20 at the time of completion of the amorphous transformer. As can also be assumed from Figure 5, since the corners of the amorphous core 9 are where the ends of the outermost layer of the amorphous thin film are located, the importance and effect of the present invention for strengthening protection by paying attention to this can be understood.

[0044] Since the structure of the completed amorphous transformer itself is equivalent to that of the currently commonly used amorphous transformer except for the shape of the insulating member 20 and the method of its manufacturing process, the illustration of the completed amorphous transformer is omitted for the purpose of avoiding redundant description.

[0045] Note that the technical idea and effect of the present invention have been mainly described from the shape aspect so far.

[0046] On the one hand, from the perspective of the manufacturing method, the formation of the insulating member 20 by the manufacturing process described in this embodiment also has a manufacturing method feature that when avoiding the corners from being shorter than other parts of the circumference or forming ridges or long parts at the corners, one insulating member base is processed and formed in the manner of origami. Of course, the manufacturing method is not particularly limited as long as the completed shape leads to the same technical idea as the shape described in the present invention.

[0047] However, the formation of the insulating member in the manner of origami described in this embodiment has a remarkable feature that no waste members are generated and ridges or long parts can be surely formed at the corners, and it can realize the facilitation of manufacturing. Therefore, it is a very suitable manufacturing method for realizing the technical idea of the present application.

Example

[0048] The basic technical idea of this example is the same as that of Example 1.

[0049] FIG. 6A is an explanatory diagram showing the initial shape of the insulating member used in this embodiment, which corresponds to FIG. 1A. As the primary processing for the insulating member base 1, it is cut along the cutting line 2 and folded along the folding line 3. Since the insulating member base is required to be an insulating material that can be folded, kraft paper or the like can be used. As an example, it is kraft paper with a thickness of about 0.25 mm.

[0050] FIG. 6B is a three-dimensional explanatory diagram after cutting and folding on the short side of FIG. 6A. 15a is the short side, and it has a short-side folding part 15b. FIG. 6C is a three-dimensional explanatory diagram after cutting and folding on the long side of FIG. 6A. 16a is the short side, and it has a long-side folding part 16b.

[0051] After cutting and folding, stack them towards the center as shown in FIG. 1F of Example 1.

[0052] FIG. 6D is a diagram corresponding to FIG. 1J, surrounded by the short-side folding portion 15b and the long-side folding portion, and the ends thereof are integrated by attaching an insulating tape 5 as shown in FIG. 6E.

[0053] FIG. 6F corresponds to FIG. 1L, and FIG. 7 corresponds to FIG. 2.

[0054] The difference from the case of Example 1 in this example is that no distinct mountain or valley portions are formed, and the height or length of the folding portion is the same across the entire side. Also in this example, since the corners can be prevented from becoming valley portions or the lowest portions, the various effects described in Example 1 can be achieved.

Example

[0055] This example is an example when manufacturing a plurality of insulating members together.

[0056] FIG. 8 is a diagram corresponding to FIG. 1A of Example 1, and is a diagram with an image as if three FIG. 1A are connected vertically.

[0057] In addition to the single-phase type where the transformer has one set of a core and a coil, there is a polyphase counterpart, for example, a three-layer type, in which a transformer group is configured by a combination of a plurality of cores and coils. When creating an insulating member 20 for such a polyphase type, by using an insulating member base body 1 as shown in FIG. 8 where a plurality of FIG. 1A are arranged in parallel, it is possible to form the necessary number of insulating members 20 for each phase together. Since the manufacturing method is the same as that in Example 1 and Example 2, the description is omitted.

[0058] When forming insulating members for each phase for a polyphase type transformer, of course, it is also possible to use individual insulating member base bodies for each phase. However, by forming the insulating members for each phase from the same insulating member base body as in this example, variations in the constituent materials of the insulating members used for each phase and manufacturing lot variations can be eliminated. Therefore, according to the technical idea of the example, it is possible to improve the manufacturing traceability of the polyphase transformer and suppress variations in reliability.

[0059] The above has described the idea and concept of the invention of the present application using various embodiments. Of course, cases realized by combining the embodiments are also included in the scope of the invention of the present application. Furthermore, as long as the disclosed ideas and concepts are used, their modifications and similar examples are also included in the scope of the invention of the present application.

[0060] In addition, an example of the invention of the present application described using each of the above embodiments can also be expressed as follows. <Part 1> In an amorphous transformer having an insulating member in which a flat portion corresponding to the plane of the coil is provided and a folded portion is disposed between the inner peripheral surface of the coil and the outer peripheral surface of the amorphous core, the amorphous transformer in which the folded portion of the insulating member has a structure that avoids the length at the corner being shorter than other portions of the side. <Part 2> In the amorphous transformer according to <Part 1>, the folded portion abuts against the folded portions of the other sides at the corner. <Part 3> In the amorphous transformer according to <Part 2>, the folded portions are formed in a full circumference by the butting. <Part 4> In the amorphous transformer according to <Part 3>, the folded portion is integrated with the folded portions of the other sides at the corner by an insulating tape. <Part 5> In the amorphous transformer according to <Part 4>, the folded portion has a region where a plurality of folded portions overlap in the middle of the side. <Part 6> In the amorphous transformer according to <Part 4>, the folded portion is the longest at the corner. <Part 7> In the amorphous transformer according to <Part 6>, the corner of the folded portion is composed of two folded portions having different lengths. <Part 8> The amorphous transformer according to <The 7>, wherein the folded portion is adhered to the inner peripheral surface of the coil. <The 9> The amorphous transformer according to <The 8>, wherein the insulating member has a region where a plurality of insulating members overlap in a flat portion corresponding to the plane of the coil. <The 10> The amorphous transformer according to <The 9>, wherein in the region where a plurality of insulating members overlap in the flat portion, the plurality of insulating members are integrated with an insulating tape. <The 11> The amorphous transformer according to <The 4>, wherein the folded portion has a uniform length on each side and a varying length at the corners. <The 12> The amorphous transformer according to <The 11>, wherein the folded portion is adhered to the inner peripheral surface of the coil. <The 13> The amorphous transformer according to <The 12>, wherein the insulating member has a region where a plurality of insulating members overlap in a flat portion corresponding to the plane of the coil. <The 14> The amorphous transformer according to <The 13>, wherein in the region where a plurality of insulating members overlap in the flat portion, the plurality of insulating members are integrated with an insulating tape. <The 15> The amorphous transformer according to <The 2>, wherein at the corners, the folded portions are butted against each other orthogonally.

Explanation of Reference Numerals

[0061] 1: Insulating member matrix 2: Cutting line 3: Folding line 5: Insulating tape 8: Coil 9: Amorphous core 11a, 12a, 13a, 14a: Cut member 11b, 12b, 13b, 14b: Long-side folding portions 11c, 12c, 13c, 14c: Short-side folding portions 20: Insulating member

Claims

1. In an amorphous transformer having an insulating member in which a flat portion corresponding to the plane of the coil is provided and a folded portion is disposed between the inner peripheral surface of the coil and the outer peripheral surface of the amorphous core, The amorphous transformer, wherein the folded portion of the insulating member has a structure that avoids the length at the corner portion from being shorter than the other portions of the side.

2. The amorphous transformer according to claim 1, wherein the folded portion abuts against the folded portions of the other sides at the corner portions.

3. The amorphous transformer according to claim 2, wherein the folded portions are formed in the entire circumference by the butt joint.

4. The amorphous transformer according to claim 3, wherein the folded portions are integrated with adjacent sides by insulating tape at the butt joint portions.

5. The amorphous transformer according to claim 4, wherein the folded portion has a region where a plurality of folded portions overlap in the middle of the side.

6. The amorphous transformer according to claim 5, wherein the folded portion is the longest at the corner portion.

7. The amorphous transformer according to claim 6, wherein the corner portion of the folded portion is composed of two folded portions having different lengths.

8. The amorphous transformer according to claim 7, wherein the folded portion is adhered to the inner peripheral surface of the coil.

9. The amorphous transformer according to claim 8, wherein the insulating member has a region where a plurality of insulating members overlap at the flat portion corresponding to the plane of the coil.

10. The amorphous transformer according to claim 9, wherein the plurality of insulating members are integrated with insulating tape in the region where the plurality of insulating members overlap at the flat portion.

11. The amorphous transformer according to claim 4, wherein the folded portion has a uniform length on each side and a variable length at the corner portion.

12. The amorphous transformer according to claim 11, wherein the folded portion is adhered to the inner peripheral surface of the coil.

13. The amorphous transformer according to claim 12, wherein the insulating member has a region where a plurality of insulating members overlap at the flat portion corresponding to the plane of the coil.

14. In the amorphous transformer according to claim 13, in a region where a plurality of insulating members overlap at the flat portion, the amorphous transformer in which the plurality of insulating members are integrated with an insulating tape.

15. In the amorphous transformer according to claim 2, the folded portion is an amorphous transformer that abuts orthogonally at the corner portion.

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