Amorphous transformer

Abstract

The present invention improves the reliability of an amorphous transformer. An amorphous transformer comprising an insulation member having a flat part corresponding to the plane of a coil and folded parts disposed between an inner peripheral surface of the coil and an outer peripheral surface of an amorphous iron core, wherein the folded parts of the insulation member are structured such that the lengths at corner parts are prevented from being shorter than the other parts of the sides.

Description

Amorphous transformer

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

[0002] Amorphous transformers that use a laminate of amorphous thin films in the iron core are known as transformers with high power conversion efficiency and excellent environmental performance. One example of such transformers is disclosed in Patent Document 1.

[0003] Japanese Patent Application Publication No. 8-31667

[0004] Patent Document 1 discloses that when inserting an amorphous core into a coil, a second insulating member 3 is installed at the end of the coil before inserting the amorphous core in order to prevent amorphous debris from entering the coil. The method described in Patent Document 1 is considered to achieve the intended purpose. However, the inventors of the present application felt that further improving the reliability of preventing debris from entering would be more desirable in order to further improve the reliability of amorphous transformers.

[0005] Therefore, the present invention aims to provide an amorphous transformer that can better prevent amorphous fragments from entering the coil.

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

[0007] 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, wherein the folded portion of the insulating member is structured to prevent the length at the corners from being shorter than the other parts of the sides.

[0008] According to the amorphous transformer of the present invention, the intrusion of amorphous fragments into the coil can be more reliably prevented, thereby improving the reliability of the amorphous transformer.

[0009] Further means and effects of the present invention will become apparent throughout the entire specification below.

[0010] 1G is an explanatory diagram showing the initial shape of an insulating member used in an embodiment of the present invention. FIG. 1G is an explanatory diagram showing the shape of an insulating member used in an embodiment of the present invention after primary processing. FIG. 1C is an explanatory diagram for explaining the shape of an insulating member used in an embodiment of the present invention. FIG. 1C is a three-dimensional view as seen from the X direction. FIG. 1C is a three-dimensional view as seen from the Y direction. FIG. 1C is a schematic explanatory diagram showing the state of secondary processing of an insulating member used in an embodiment of the present invention. FIG. 1G is an explanatory diagram showing the shape of an insulating member used in an embodiment of the present invention after secondary processing. FIG. 1G is an explanatory three-dimensional view as seen from the A-A line in FIG. 1G. FIG. 1G is an explanatory three-dimensional view as seen from the B-B line in FIG. 1G. FIG. 1G is an explanatory three-dimensional view showing the shape of an insulating member used in an embodiment of the present invention after secondary processing. FIG. 1G is an explanatory three-dimensional view showing the shape of an insulating member used in an embodiment of the present invention after tertiary processing. FIG. 1G is an explanatory diagram showing the shape of an insulating member used in an embodiment of the present invention after fourth processing. FIG. 1G is an explanatory plan view of an insulating member used in an embodiment of the present invention after a coil has been inserted. FIG. 1G is a cross-sectional ... 6A is an explanatory diagram showing the positional relationship between an insulating member, an amorphous core, and a coil of an amorphous transformer used in one embodiment of the present invention. FIG. 6B is an explanatory diagram showing the initial shape of an insulating member used in another embodiment of the present invention. FIG. 6A is a three-dimensional diagram explaining the shape after primary processing of the side that was the short side before cutting in FIG. 6A. FIG. 6B is a three-dimensional diagram explaining the shape after primary processing of the side that was the long side before cutting in FIG. 6A. FIG. 6B is an explanatory three-dimensional diagram showing the shape after secondary processing of an insulating member used in another embodiment of the present invention. FIG. 6C is an explanatory three-dimensional diagram showing the shape after tertiary processing of an insulating member used in another embodiment of the present invention. FIG. 6D is an explanatory diagram showing the shape after quaternary processing of an insulating member used in another embodiment of the present invention. FIG. 6E is an explanatory plan view of an insulating member used in another embodiment of the present invention after a coil has been inserted. FIG. 6F is an explanatory diagram showing the initial shape of an insulating member used in another embodiment of the present invention.

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

[0012] 1A is an explanatory diagram showing the initial shape of an insulating member used in one embodiment of the present invention. As a primary process, an insulating member substrate 1 is cut along cutting lines 2 and folded along folding lines 3. The insulating member substrate is required to be made of an insulating material that can be folded, so kraft paper or the like can be used. One example is kraft paper with a thickness of approximately 0.25 mm.

[0013] 1B is an explanatory diagram showing an image of the shape of the insulating material substrate 1 after the primary processing. The insulating material substrate 1 is divided into four cut members 11a, 12a, 13a, and 14a. The cut members have long-side folded portions 11b, 12b, 13b, and 14b, respectively, and short-side folded portions 11c, 12c, 13c, and 14c, respectively.

[0014] 1C is an explanatory diagram for explaining the shape of 11a, which defines the X and Y directions and makes it easier to understand the three-dimensional shape.

[0015] Fig. 1D is a three-dimensional view seen from the X direction in Fig. 1C. The insulating member body 1 is folded at the folding portion to form a long-side folding portion 11b.

[0016] Fig. 1E is a three-dimensional view seen from the Y direction in Fig. 1C. The insulating member body 1 is folded at the folding portion to form a short-side folding portion 11c.

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

[0018] 1F is an explanatory diagram showing the secondary processing in which a total of four members 11a, 12a, 13a, and 14a are moved toward the center. In this secondary processing, 11a, 12a, 13a, and 14a are moved toward the center so that they ultimately overlap each other.

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

[0020] To facilitate understanding of the shape, the X and Y directions are set in FIG. 1G.

[0021] 1H is an explanatory diagram showing the three-dimensional structure around line A-A in FIG. 1G. On the left side is an area of ​​11a alone, and on the right side is an area of ​​12a alone. In the center, an area where 11a and 12a overlap is formed as 11a+12a.

[0022] At the same time, folded-in portions 11b and 12b are formed. A feature of this is that the upright portions formed by the two folded sides are longest at the corners and shortest near the center. In other words, it can be said that peaks are formed at the corners and valleys are formed in the center. It can also be said that the highest or longest structure is formed at the corners. Furthermore, it can be said that the structure prevents the length or height of the corners from being shorter or shorter than the rest of the side.

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

[0024] 1J is an explanatory diagram showing the shape after secondary processing, in order to understand the situation when FIG. 1H and FIG. 1I are superimposed, and is a three-dimensional view of the upper left corner of FIG. 1G. As is clear from the figure, the insulating member is configured to be longest or tallest at the corner by 14c and 12b.

[0025] 1K is a diagram showing the third processing step of attaching insulating tape 5 to the circuit board shown in FIG. 1J. This integrates 14c and 12b, completing the insulating structure.

[0026] Similarly, the other corners are also structured and treated in the same way so that the corners are not the lowest part around the entire circumference, i.e., the corners are prevented from being shorter than the rest of the circumference.

[0027] Here, let us look at the structure disclosed in Patent Document 1. For example, Figure 6 discloses a structure in which the second insulating member is bent. The concept of bending itself is similar to that explained in this embodiment. The differences lie in the method of bending and the structural parts realized by bending.

[0028] In the structure disclosed in Patent Document 1, as shown in Figure 6 and other figures, the folded-in portion is the shortest at the corner. In other words, the corner becomes a valley.

[0029] On the other hand, if we consider the purpose of the present invention again, which is to prevent amorphous fragments from entering the coil when inserting the amorphous core into the coil, the inventors of the present invention investigated which parts of the amorphous core are most likely to produce amorphous fragments when inserting the amorphous core into the coil, and found that it is the corners.

[0030] This is because the amorphous core is constructed by laminating amorphous thin films, and at the corners, the edge of the outermost layer of the amorphous thin film faces the corner of the coil, making it the weakest point, so to speak, prone to structural damage or fragments falling off when an external force such as contact is applied.

[0031] For this reason, the inventors of the present application have discovered that in order to further improve the reliability of preventing debris from entering and further improve the reliability of amorphous transformers, the optimal structural solution is to expand the protection area at the corners.

[0032] Therefore, in the present invention, in contrast to the structure ultimately disclosed in Patent Document 1, in which the insulating member becomes a valley at the corner, the intention is to provide a structure in which the corner does not become a valley in order to actively protect the corner.

[0033] In this embodiment, as an example, the insulating material is prevented from becoming the shortest around the corner. This strengthens protection at the corner and reduces the risk of amorphous fragments falling off and their impact. The effect of the present invention is significantly different from that of Patent Document 1 at this stage. Therefore, at this stage, the present invention claims its technical concept and effect.

[0034] In the case of Patent Document 1, there is no folded-in portion at the corners. In contrast, in the technical concept of the present invention, the folded-in portion can be said to abut against the folded-in portion on another side at the corners.

[0035] Furthermore, it can be said that the folded portion is formed around the entire circumference by the butting, thereby realizing protection and suppression of amorphous fragments from falling out of the amorphous iron core over the entire assembly.

[0036] In this case, it can also be said that the two adjacent folded-in portions at the corners are butted against each other at right angles, thereby realizing protection of the corners without any gaps.

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

[0038] Next, as a tertiary process, in Fig. 1L corresponding to Fig. 1G, insulating tape 5 is also applied to the overlapping portions of the planar insulating members, and the whole is integrated. In this way, insulating member 20 is completed.

[0039] 2 is a plan view showing the state in which the insulating member 20 is grounded to the coil 8. The folded portion of the insulating member 20 is shaped to be positioned inside the inner periphery of the coil 8.

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

[0041] Fig. 4 is a schematic three-dimensional diagram similar to Fig. 3, illustrating the three-dimensional shape of another 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 Fig. 3 corresponds to the folded portions on the long side, such as 11b, 12b, 13b, and 14b in Fig. 1, and 22 in Fig. 4 corresponds to the folded portions on the short side, such as 11c, 12c, 13c, and 14c in Fig. 1.

[0042] These folded portions are then fixed to the coil 8 with adhesive or the like, thereby preventing the amorphous core from getting caught when inserted, and further preventing the generation and falling off of amorphous fragments.

[0043] Figure 5 is a diagram in which the positional relationship of the amorphous core 9 is added to Figure 2. It is an explanatory diagram of the insulating planar structure around the insulating member 20 when the amorphous transformer is completed. As can be assumed from Figure 5, the corners of the amorphous core 9 are where the ends of the outermost layer of the amorphous thin film are located, so by focusing on these corners, the importance and effect of the present invention, which strengthens protection, can be understood.

[0044] The structure of the completed amorphous transformer itself is the same as that of amorphous transformers currently in general use, except for the shape of the insulating member 20 and the method of its manufacturing process, so the illustration of the completed amorphous transformer has been omitted in order to avoid redundancy in the description.

[0045] The technical ideas and effects of the present invention have been described above mainly from the perspective of shape.

[0046] On the other hand, from the viewpoint of the manufacturing method, the formation of insulating member 20 by the manufacturing process described in this embodiment has the characteristic of processing and forming a single insulating member base body in an origami-like manner to prevent corners from being shorter than the rest of the circumference or to form peaks or long portions at the corners. Of course, there are no particular limitations on the manufacturing method as long as the shape of the finished system achieves the same technical concept as the shape described in the present invention.

[0047] However, the formation of insulating members in the manner of origami described in this embodiment has the notable feature of not producing any unnecessary material and being able to reliably form ridges or long portions at corners, and also simplifies manufacturing, making it an extremely suitable manufacturing method for realizing the technical concept of the present application.

[0048] The basic technical concept of this embodiment is the same as that of the first embodiment.

[0049] 6A is an explanatory diagram showing the initial shape of the insulating member used in this example, and corresponds to FIG. 1A. As a primary process, an insulating member substrate 1 is cut along cutting lines 2 and folded along folding lines 3. The insulating member substrate is required to be made of an insulating material that can be folded, so kraft paper or the like can be used. One example is kraft paper with a thickness of approximately 0.25 mm.

[0050] Fig. 6B is a three-dimensional explanatory diagram of the short side of Fig. 6A after cutting and folding. 15a is the short side, and has a short side fold-in portion 15b. Fig. 6C is a three-dimensional explanatory diagram of the long side of Fig. 6A after cutting and folding. 16a is the short side, and has a long side fold-in portion 16b.

[0051] After cutting and folding, the pieces are stacked together at the center as shown in FIG. 1F of Example 1.

[0052] FIG. 6D is a view corresponding to FIG. 1J, and is surrounded by the short-side folded-in portions 15b and the long-side folded-in portions, and the ends are integrated by adhering insulating tape 5 as shown in FIG. 6E.

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

[0054] This embodiment differs from the first embodiment in that no clear peaks or valleys are formed, and the height or length of the folded-in portion is the same over the entire side. This embodiment also prevents corners from becoming valleys or lowest points, and therefore provides the various effects described in the first embodiment.

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

[0056] FIG. 8 is a diagram corresponding to FIG. 1A of the first embodiment, and is an image of three FIG. 1A connected vertically.

[0057] In addition to single-phase transformers, which have one iron core and one coil, there are also multi-phase transformers, such as three-layer transformers, in which a group of transformers is formed by combining multiple iron cores and coils. When creating an insulating member 20 for such a multi-phase type, by using an insulating member base 1 having multiple parallel insulating members 1A as shown in Fig. 8, it is possible to form the required number of insulating members 20 for all phases. The method of creation is the same as in Examples 1 and 2, and therefore a description thereof will be omitted.

[0058] When forming insulating members for the number of phases of a multi-phase transformer, it is of course possible to use individual insulating member bases for each phase. However, as in this embodiment, by forming insulating members for the number of phases from the same insulating member base, it is possible to eliminate variations in the constituent materials of the insulating members used for each phase and variations in manufacturing lots. Therefore, according to the technical concept of this embodiment, it is possible to improve the manufacturing traceability of multi-phase transformers and suppress variations in reliability.

[0059] The above examples illustrate the ideas and concepts of the present invention. Of course, the scope of the present invention also includes examples that are realized by combining the examples. Furthermore, as long as the disclosed ideas and concepts are used, any modifications or similar examples are also included within the scope of the present invention.

[0060] Furthermore, one example of the invention of the present application described using the above embodiments can also be expressed as follows. <No. 1> An amorphous transformer having an insulating member with a flat portion corresponding to the plane of the coil and a folded portion disposed between the inner peripheral surface of the coil and the outer peripheral surface of the amorphous core, wherein the folded portion of the insulating member is configured to prevent the length at corners from being shorter than the rest of the sides. <No. 2> An amorphous transformer according to <No. 1>, wherein the folded portion butts up against a folded portion of another side at a corner. <No. 3> An amorphous transformer according to <No. 2>, wherein the folded portion is formed around the entire circumference by the butting. <No. 4> An amorphous transformer according to <No. 3>, wherein the folded portion is formed around the entire circumference by the butting. <No. 5> The amorphous transformer according to <No. 4>, wherein the folded portion has a region where multiple folded portions overlap in the middle of a side. <No. 6> The amorphous transformer according to <No. 4>, wherein the folded portion is longest at a corner. <No. 7> The amorphous transformer according to <No. 6>, wherein the corner of the folded portion is composed of two folded portions of different lengths. <No. 8> The amorphous transformer according to <No. 7>, wherein the folded portion is bonded to the inner peripheral surface of the coil. <No. 9> The amorphous transformer according to <No. 8>, wherein the insulating member has a region where multiple insulating members overlap in a flat portion corresponding to the plane of the coil. <No. 10> The amorphous transformer according to <No. 9>, wherein the plurality of insulating members are integrated with insulating tape in the area where they overlap on the flat portion. <No. 11> The amorphous transformer according to <No. 4>, wherein the folded portion has a uniform length on each side and varies in length at the corners. <No. 12> The amorphous transformer according to <No. 11>, wherein the folded portion is adhered to the inner circumferential surface of the coil.<No. 13> The amorphous transformer according to <No. 12>, wherein the insulating member has a region where multiple insulating members overlap in a flat portion corresponding to the plane of the coil. <No. 14> The amorphous transformer according to <No. 13>, wherein the multiple insulating members are integrated with insulating tape in the region where the multiple insulating members overlap in the flat portion. <No. 15> The amorphous transformer according to <No. 2>, wherein the folded portions butt each other orthogonally at the corners.

[0061] 1: Insulating material base body 2: Cutting line 3: Folding line 5: Insulating tape 8: Coil 9: Amorphous iron core 11a, 12a, 13a, 14a: Cutting member 11b, 12b, 13b, 14b: Folded portion on long side 11c, 12c, 13c, 14c: Folded portion on short side 20: Insulating material

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 folded portion of the insulating member has a structure that avoids the length at the corner being shorter than the other portions of the side. An amorphous transformer.

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

3. The amorphous transformer according to claim 2, wherein the folded portions are formed in a full circumference by the abutment. An amorphous transformer.

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

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. An amorphous transformer.

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

7. The amorphous transformer according to claim 6, wherein the corners of the folded portion are constituted by two folded portions having different lengths. An amorphous transformer.

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

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

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 in the flat portion. An amorphous transformer.

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

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

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

14. The amorphous transformer according to claim 13, wherein in a region where a plurality of insulating members are stacked on the flat portion, the plurality of insulating members are integrated with an insulating tape.

15. The amorphous transformer according to claim 2, wherein the folded portion is butted orthogonally at the corner portion.

Images