Reactor core

Abstract

To reduce the cost and the difficulty in manufacturing a reactor core.SOLUTION: A reactor core (1) has an auxiliary core (5) which forms a bypass path of magnetic flux. The auxiliary core (5) includes: a first tabular end core (51) which extends from a through-hole (2A) to a yoke end (23) side; and a second tabular end core (52) which connects the first end core (51) to the yoke end (23). A lamination direction of silicon steel plates in the first end core (51) is different from that in the second end core (52).SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present disclosure relates to a reactor core. [Background technology]

[0002] Conventionally, a reactor core has been known in which leg cores are arranged between upper and lower yoke cores and fastened to each other by studs that pass through through holes in the yoke cores and into the centers of the leg cores. Regarding this type of reactor core, Patent Document 1 discloses a structure in which a U-shaped auxiliary core is attached to the end of the yoke core to form a bypass path for magnetic flux in order to reduce loss due to eddy currents that occur when magnetic flux bypasses the through holes in the yoke core. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 63-186407 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the U-shaped auxiliary core as described above has the problem of being expensive and difficult to manufacture.

[0005] One aspect of the present disclosure has been made in view of the above-described problems, and aims to reduce the manufacturing cost and difficulty of a reactor core having a bypass path for magnetic flux. [Means for solving the problem]

[0006] In order to solve the above problem, a reactor core according to one embodiment of the present disclosure is a reactor core in which a plurality of leg cores are arranged between a pair of yoke cores, and the pair of yoke cores and the leg cores are fastened together by through holes provided in the pair of yoke cores and studs that penetrate the centers of the leg cores, and the reactor core further comprises an auxiliary core made of laminated magnetic steel plates that is provided at the end of the yoke core and forms a bypass path for magnetic flux in the portion where the magnetic path is blocked by the through hole, and the auxiliary core includes a flat first end core that extends from the through hole toward the end of the yoke core, and a flat second end core that connects the first end core and the end of the yoke core, and the magnetic steel plates of the first end core and the second end core have different lamination directions. [Effects of the Invention]

[0007] According to one aspect of the present invention, it is possible to reduce the manufacturing cost and difficulty of a reactor core having a bypass path for magnetic flux. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 2 is a front view illustrating a configuration example of a reactor core according to an embodiment of the present disclosure. [Figure 2] 2 is a plan view showing a configuration example of the reactor core shown in FIG. 1. FIG. [Figure 3] FIG. 4 is a plan view showing an end structure of a yoke core included in the reactor core. [Figure 4] 4 is a plan view showing a state in which an auxiliary core is attached to the yoke core shown in FIG. 3. [Figure 5] FIG. 2 is a front view showing the flow of magnetic flux in the reactor core. [Figure 6] 6 is a plan view showing the flow of magnetic flux in the reactor core shown in FIG. 5. FIG. [Figure 7] FIG. 10 is a plan view showing a modified example of the reactor core. [Figure 8] FIG. 10 is a front view showing a configuration example of another modified example of the reactor core. [Figure 9]9 is a plan view showing a configuration example of the reactor core shown in FIG. 8. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0009] An embodiment of the present disclosure will be described below. Note that the following description is an example of a reactor core according to the present disclosure, and the technical scope of the present disclosure is not limited to the illustrated example.

[0010] [Reactor core configuration] First, a configuration example of a reactor core 1 according to this embodiment will be described with reference to Fig. 1 to Fig. 4. Fig. 1 is a front view showing the configuration example of the reactor core 1 according to this embodiment. Fig. 2 is a plan view showing the configuration example of the reactor core 1 shown in Fig. 1.

[0011] 1 and 2, reactor core 1 includes a pair of yoke cores 2 including an upper yoke core 21 and a lower yoke core 22, and a plurality of leg cores 3 arranged between the pair of yoke cores 2. Reactor core 1 also includes studs 4 that penetrate through holes 2A provided in the pair of yoke cores 2 and centers 3A of the leg cores 3. Reactor core 1 has a structure in which the pair of yoke cores 2 and the leg cores 3 are fastened together by the studs 4, thereby providing a fixed support.

[0012] This reactor core 1 further includes auxiliary cores 5 provided at both ends of the upper yoke core 21 and the lower yoke core 22. The auxiliary cores 5 form a bypass path for magnetic flux to reduce loss due to eddy currents that occur when magnetic flux flowing from the leg cores 3 into the upper yoke core 21 and the lower yoke core 22 bypasses the through hole 2A of the yoke core 2. In the reactor core 1, the auxiliary core 5 has a structure that combines a flat first end core 51 and a flat second end core 52. Therefore, the reactor core 1 can reduce manufacturing costs and difficulty compared to conventional reactor cores that include a U-shaped auxiliary core.

[0013] In the following, the direction in which the pair of yoke cores 2 face each other may be referred to as the up-down direction (vertical direction), the longitudinal direction of the yoke core 2 in which the leg cores 3 are lined up may be referred to as the left-right direction, and the short side direction of the yoke core 2 that is perpendicular to the up-down and left-right directions may be referred to as the front-rear direction. In each drawing, the right side in the left-right direction is shown as the +X direction, the rear side in the front-rear direction is shown as the +Y direction, and the upper side in the up-down direction is shown as the +Z direction.

[0014] The pair of yoke cores 2 includes an upper yoke core 21 and a lower yoke core 22 that face each other in the vertical direction. The upper yoke core 21 is a yoke core that is connected to the vertically upper end of the leg core 3 when the reactor core 1 is in use. The lower yoke core 22 is a yoke core that is connected to the vertically lower end of the leg core 3 when the reactor core 1 is in use.

[0015] The upper yoke core 21 and the lower yoke core 22 are magnetically coupled to both ends of the leg cores 3. The upper yoke core 21 and the lower yoke core 22 are formed, for example, by stacking a plurality of silicon steel plates (magnetic steel plates) in the front-to-back direction (Y direction). In other words, the silicon steel plates that make up the upper yoke core 21 and the lower yoke core 22 are stacked with their planes perpendicular to the front-to-back direction.

[0016] The leg core 3 is an iron core around which, for example, a winding (not shown) is wound. The leg core 3 includes blocks 31 and gaps 32. The leg core 3 is configured by stacking the blocks 31 and the gaps 32 alternately in a required number of stages.

[0017] The blocks 31 are magnetic blocks. The blocks 31 are made of, for example, silicon steel plates stacked in the radial direction. Gaps 32 are arranged between the multiple blocks 31. The gaps 32 are made of a non-magnetic and insulating material. The multiple blocks 31 are bonded together with resin or the like via the gaps 32. In the example shown in FIG. 1, three leg cores 3 are arranged side by side in the left-right direction.

[0018] The pair of yoke cores 2 have square-shaped through-holes 2A at the positions where the leg cores 3 are to be placed. The leg cores 3 have a hollow center 3A. Studs 4 are provided so as to pass through the through-holes 2A of the pair of yoke cores 2 and the center 3A of the leg cores 3. Clamp members 6 are provided at both ends of the studs 4 to clamp the pair of yoke cores 2 and leg cores 3 together, and the clamp members 6 fasten the pair of yoke cores 2 and leg cores 3 together.

[0019] Fig. 3 is a plan view showing the end structure of the yoke core 2. Fig. 3 illustrates the yoke end 23 on the right side of the upper yoke core 21, out of four yoke ends (ends of the yoke core) 23 that are the ends of the pair of yoke cores 2 in the left-right direction, and shows a state in which the auxiliary core 5 and the like are not attached.

[0020] As shown in Fig. 3, upper yoke core 21 is formed by stacking multiple silicon steel plates in the front-to-rear direction (Y direction). Upper yoke core 21 is provided with a notch 24 in the center of yoke end 23 in the front-to-rear direction in plan view, for forming through hole 2A through which stud 4 passes. Upper yoke core 21 is also provided with a protrusion 23A in advance, which is a part of yoke end 23 that protrudes, for connecting auxiliary core 5. In the illustrated example, a pair of protrusions 23A is provided parallel to each other on both sides of yoke end 23 in the front-to-rear direction in plan view.

[0021] Fig. 4 is a plan view showing the state in which auxiliary core 5 and the like are attached to upper yoke core 21 shown in Fig. 3. As shown in Fig. 4, auxiliary core 5 is provided at yoke end 23, and forms a bypass path for magnetic flux in the portion where the magnetic path is blocked by through hole 2A.

[0022] The auxiliary core 5 includes a flat first end core 51 extending from the through hole 2A toward the yoke end 23, and a flat second end core 52 connecting the first end core 51 and the protrusion 23A of the yoke end 23.

[0023] The first end core 51 is inserted into the cutout 24 so as to leave a square-shaped through hole 2A through which the stud 4 passes. As a result, one end (left end) of the first end core 51 forms part of the inner circumferential surface of the through hole 2A, and the other end (right end) protrudes from the yoke end 23 and is arranged parallel to the protruding portion 23A of the yoke end 23.

[0024] This first end core 51 is formed by, for example, stacking multiple silicon steel plates in the front-to-rear direction (Y direction). In other words, the stacking direction of the silicon steel plates of the upper yoke core 21 and the first end core 51 is the same. This allows magnetic flux that has flowed into the first end core 51 to easily move toward the second end core 52 along the plane of the silicon steel plates.

[0025] Additionally, an insulating plate 7 is provided between the first end core 51 and the cutout 24. This insulating plate 7 prevents magnetic flux from penetrating the plane of the silicon steel plate and moving from the first end core 51 to the upper yoke core 21.

[0026] The second end core 52 connects the first end core 51 and the protruding portion 23A of the yoke end portion 23. The center portion of the second end core 52 in the front-to-rear direction is connected to the other end side of the first end core 51, and both ends in the front-to-rear direction are connected to the pair of protruding portions 23A. In other words, the auxiliary core 5 has the first end core 51 and the second end core 52 connected in a T-shape in plan view.

[0027] In the auxiliary core 5, the first end core 51 and the second end core 52 have silicon steel plate lamination directions that are different from each other. In the reactor core 1, the second end core 52 is formed, for example, by stacking multiple silicon steel plates in the vertical direction (Z direction). That is, the silicon steel plates that make up the second end core 52 are stacked with their planes perpendicular to the vertical direction. Therefore, the first end core 51 and the second end core 52 have silicon steel plate lamination directions that are perpendicular to each other.

[0028] The method for connecting (coupling) first end core 51 and second end core 52 and the method for connecting (coupling) second end core 52 and protruding portion 23A are not particularly limited, and may be connected using, for example, a bolt, etc. Also, an insulating material may be inserted between first end core 51 and second end core 52, and between second end core 52 and protruding portion 23A.

[0029] [Flow of magnetic flux in reactor core] Next, the flow of magnetic flux in the reactor core 1 will be described with reference to Fig. 5 and Fig. 6. Fig. 5 is a front view showing the flow of magnetic flux in the reactor core 1. Fig. 6 is a plan view showing the flow of magnetic flux in the reactor core 1 shown in Fig. 5.

[0030] 5 and 6, in reactor core 1, magnetic flux generated in leg cores 3 flows into first end core 51. Like upper yoke core 21, first end core 51 is made up of silicon steel plates stacked in the front-to-rear direction. Therefore, the magnetic flux that has flowed into first end core 51 moves toward second end core 52 along the plane of the silicon steel plates.

[0031] Next, the magnetic flux that has traveled through first end core 51 flows from first end core 51 into second end core 52. Second end core 52 is made up of silicon steel plates stacked in the vertical direction. Therefore, the magnetic flux that has flowed into second end core 52 flows along the plane of the silicon steel plates from the center of second end core 52 to the protruding portion 23A side of yoke end 23.

[0032] Finally, the magnetic flux that has moved through second end core 52 flows from second end core 52 into protruding portion 23A of yoke end 23, and is returned to upper yoke core 21.

[0033] In this way, in reactor core 1, magnetic flux generated in leg cores 3 is returned to upper yoke core 21 via the bypass path formed by auxiliary core 5. To prevent the formation of a magnetic path in which magnetic flux penetrates the plane of the silicon steel plate in this bypass path, the lamination directions of the silicon steel plates of first end core 51 and second end core 52 are different from each other. As a result, magnetic flux moves along the plane of the silicon steel plate without penetrating it, thereby reducing loss due to eddy currents.

[0034] In the above explanation, the explanation has focused on one end of the upper yoke core 21, but it goes without saying that the application of the auxiliary core 5 to the other end of the pair of yoke cores 2 can also reduce losses due to eddy currents.

[0035] Furthermore, in the above explanation, a configuration example has been described in which protrusion 23A is provided on yoke end 23 to connect yoke core 2 and auxiliary core 5, but instead of protrusion 23A, a part of auxiliary core 5 may protrude toward yoke end 23. In other words, auxiliary core 5 may be provided with a configuration equivalent to protrusion 23A. In this case, auxiliary core 5 may further include a flat third end core that connects second end core 52 and yoke end 23, and the lamination direction of the silicon steel plates of this third end core may be the same as that of yoke core 2.

[0036] [Effect of reactor core] As described above, the reactor core 1 according to this embodiment is a reactor core 1 in which a plurality of leg cores 3 are arranged between a pair of yoke cores 2, and the pair of yoke cores 2 and the leg cores 3 are fastened together by studs 4 that penetrate through holes 2A provided in the pair of yoke cores 2 and centers 3A of the leg cores 3, and is provided with an auxiliary core 5 made of laminated silicon steel plates that is provided at yoke end 23, which is the end of yoke core 2, and forms a bypass path for magnetic flux in the portion of the magnetic path blocked by through hole 2A. This auxiliary core 5 includes a flat first end core 51 that extends from through hole 2A toward yoke end 23, and a flat second end core 52 that connects first end core 51 and yoke end 23, and the lamination directions of the silicon steel plates of first end core 51 and second end core 52 are different from each other.

[0037] In the reactor core 1, the auxiliary core 5 that forms a bypass path for magnetic flux is composed of a flat first end core 51 and a flat second end core 52. This reduces the manufacturing cost and difficulty of the auxiliary core 5 compared to conventional U-shaped auxiliary cores. Therefore, according to this embodiment, it is possible to reduce the manufacturing cost and difficulty of the reactor core 1 that has a bypass path for magnetic flux.

[0038] Furthermore, in reactor core 1, the lamination directions of the silicon steel plates are different between first end core 51 and second end core 52. Therefore, according to this embodiment, the bypass path formed by auxiliary core 5 prevents magnetic flux from penetrating the plane of the silicon steel plates, thereby reducing loss due to eddy currents.

[0039] [Modification] (Variation 1) Fig. 7 is a plan view showing a configuration example of a reactor core 1A which is a modified example of the reactor core 1. As shown in Fig. 7, the second end core 52 may be covered by the yoke end 23.

[0040] In reactor core 1A, second end core 52 is provided without any gap at yoke end 23, without protrusion 23A in between. This eliminates the need to provide protrusion 23A at yoke end 23. This reduces the width dimension of yoke core 2 in the left-right direction, allowing reactor core 1A to be made smaller.

[0041] (Variation 2) Fig. 8 is a front view showing an example of the configuration of a reactor core 1B, which is another modified example of the reactor core 1. Fig. 9 is a plan view showing an example of the configuration of the reactor core 1A shown in Fig. 8. As shown in Figs. 8 and 9, the reactor core 1B may be a two-leg core type in which two leg cores 3 are arranged side by side in the left-right direction between a pair of yoke cores 2.

[0042] Even in the two-legged reactor core 1B, a bypass path for magnetic flux can be formed by providing auxiliary cores 5 at each of the rear left and right ends of the pair of yoke cores 2. This reduces the manufacturing cost and difficulty of the two-legged reactor core 1B having a bypass path for magnetic flux.

[0043] 〔summary〕 The reactor core according to aspect 1 of the present disclosure is a reactor core in which a plurality of leg cores are arranged between a pair of yoke cores, and the pair of yoke cores and the leg cores are fastened together by through holes provided in the pair of yoke cores and studs that penetrate the centers of the leg cores, and the reactor core is provided with an auxiliary core made of laminated magnetic steel plates (silicon steel plates) that is provided at the end (yoke end 23) of the yoke core and forms a bypass path for magnetic flux in the portion where the magnetic path is blocked by the through hole, and the auxiliary core includes a flat first end core that extends from the through hole toward the end side of the yoke core, and a flat second end core that connects the first end core and the end of the yoke core, and the magnetic steel plates of the first end core and the second end core have mutually different lamination directions.

[0044] In the above configuration, the auxiliary core that forms the magnetic flux bypass path is composed of a flat first end core and a flat second end core. Therefore, compared to a conventional U-shaped auxiliary core, the manufacturing cost and difficulty of the auxiliary core can be reduced. Therefore, with the above configuration, the manufacturing cost and difficulty of the reactor core having a magnetic flux bypass path can be reduced.

[0045] In addition, in the above configuration, the lamination directions of the magnetic steel plates of the first end core and the second end core are different from each other, which prevents the formation of a magnetic path in which magnetic flux penetrates the plane of the silicon steel plates in the bypass route formed by the auxiliary core, thereby reducing loss due to eddy currents.

[0046] In a reactor core according to aspect 2 of the present disclosure, in aspect 1, the yoke core may have a protruding portion in which a portion of the yoke end protrudes, and the second end core and the protruding portion may be connected.

[0047] According to this configuration, the magnetic flux that has flowed into the first end core can be moved to the protruding portion via the second end core 52 and returned to the yoke core.

[0048] In a reactor core according to a third aspect of the present disclosure, in the first or second aspect, the lamination directions of the first end core and the second end core may be orthogonal to each other.

[0049] According to this configuration, the bypass path formed by the auxiliary core prevents magnetic flux from forming a magnetic path that penetrates the plane of the silicon steel plate, making it easier to reduce loss due to eddy currents.

[0050] In a reactor core according to a fourth aspect of the present disclosure, in the first aspect, the second end core may be provided to cover an end of the yoke core.

[0051] This configuration eliminates the need to provide protrusions at the ends of the yoke, and therefore the width of the yoke core can be reduced, allowing the reactor core to be made smaller.

[0052] In a reactor core according to aspect 5 of the present disclosure, in any one of aspects 1 to 4, the auxiliary core may be configured such that, in a plan view, the first end core and the second end core are connected in a T-shape.

[0053] According to the above configuration, it is possible to suitably manufacture an auxiliary core having a structure in which a flat plate-shaped first end core and a flat plate-shaped second end core are combined.

[0054] The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in the embodiments are also included in the technical scope of the present invention. Furthermore, new technical features can be formed by combining the technical means disclosed in the embodiments. [Explanation of symbols]

[0055] 1, 1A, 1B: Reactor core 2: Yoke core (pair of yoke cores) 2A: Through hole 3: Leg iron core 3A: Center 4: Studs 5: Auxiliary core 21: Upper yoke core (yoke core) 22: Lower yoke core (yoke core) 23: Yoke end (end of yoke core) 23A:Protrusion 51: First end core 52: Second end core

Claims

1. A reactor core in which a plurality of leg cores are arranged between a pair of yoke cores, and the pair of yoke cores and the leg cores are fastened together by through holes provided in the pair of yoke cores and studs passing through the centers of the leg cores, an auxiliary core made of laminated magnetic steel plates, the auxiliary core being provided at an end of the yoke core and forming a bypass path for magnetic flux at a portion where the magnetic path is interrupted by the through hole; The auxiliary core is a flat first end core extending from the through hole toward the end of the yoke core; a flat second end core connecting the first end core and an end of the yoke core; Including, The first end core and the second end core have magnetic steel plates whose lamination directions are different from each other.

2. the yoke core has a protruding portion formed by a part of an end portion of the yoke core protruding, The reactor core according to claim 1 , wherein the second end core is connected to the protruding portion.

3. The reactor core according to claim 1 or 2, wherein the lamination directions of the first end core and the second end core are perpendicular to each other.

4. The reactor core according to claim 1 , wherein the second end core covers an end of the yoke core.

5. The reactor core according to claim 1 or 2, wherein the auxiliary core has the first end core and the second end core connected in a T-shape in a plan view.

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