Reactor part

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to improve the DC superimposition characteristic of a high current value while miniaturizing the core shape of the reactor component, and it is possible to reduce the size, weight, and cost of the entire reactor component by miniaturization. Regarding reactor parts.

Reactors are used in a wide variety of applications. Typical reactors are a series reactor that connects in series with the motor circuit to limit the current at the time of short circuit, a parallel reactor that stabilizes the current sharing between parallel circuits, and a parallel reactor that limits the current at the time of short circuit and protects the machine connected to it. Current limiting reactor, starting reactor that is connected in series with the motor circuit to limit the starting current, shunt reactor that is connected in parallel to the transmission line to compensate for phase-advancing ineffective power and suppress abnormal voltage, between the neutral point and the ground. Neutral point reactor used to limit the ground fault current that flows in the event of a ground fault in the power system, and an arc extinguishing reactor that automatically extinguishes the arc generated during a one-wire ground fault in the three-phase power system. There is.

Electrical components such as transformers and choke coils, including reactors, are required to satisfy predetermined electrical specifications in relation to the electric circuits used. In particular, when the reactor is used for a step-up reactor or the like of a high current circuit, it is important that the DC superimposition characteristic of a high current value satisfies the specifications.

FIG. 1 is a perspective view showing a core of a conventional reactor component. As shown in FIG. 1, the conventional core 9 is formed of, for example, several magnetic blocks 3a and 3b and a sheet material 6 inserted as a magnetic gap between the blocks. The shape of this core 9 is substantially ring-shaped as a whole, and there are two straight parts made of magnetic block 3b, and each straight part is wound via a bobbin (not shown) winding frame part. (Not shown) is wound to obtain the desired electrical characteristics. The magnetic block 3a is connected to each straight line portion, and this core 9 is formed into a substantially ring shape.

The conventional core 9 has a core shape having a uniform core cross-sectional area with respect to the magnetic path (see, for example, Patent Document 1). That is, in the core 9 shown in FIG. 1, the height Ha of the magnetic block 3a and the height Hb of the magnetic block 3b are formed to have the same dimensions, and the width Wa of the magnetic block 3a and the magnetic material The width Wb of block 3b was also formed to the same dimensions. Therefore, the cross-sectional area of the magnetic block 3b forming the winding portion where the winding is wound and the magnetic block 3a forming the non-winding portion where the winding is not wound are both orthogonal to the magnetic path. The core shape was such that

<patcit num="1"><text>Japanese Unexamined Patent Publication No. 2003-124039</text></patcit>

<p> As shown in FIG. 1, the above-mentioned conventional reactor component has a core shape having a uniform core cross-sectional area with respect to the magnetic path, so that the shape of the core 9 becomes large and the cost increases. was there. If the shape of the core 9 is large, it is difficult to reduce the size and weight of the entire reactor, and since the core is the most expensive material among the parts of the reactor, it is difficult to reduce the cost of the entire reactor.</p><p> A first object of the present invention is to provide a technique capable of reducing the size, weight, and cost of the entire reactor by reducing the core shape of the reactor component.</p><p> A second object of the present invention is to improve the DC superimposition characteristics in a high current region while reducing the core shape of the reactor component, and to reduce the size and weight of the entire reactor by reducing the core shape. The purpose is to provide technology that enables cost reduction and cost reduction.</p>

<p> In the design of the core of the reactor component, it has been generally practiced to design the magnetic path with the same cross-sectional shape, but the present inventor has reduced the portion through which the magnetic flux hardly passes to achieve a high current region. It was found that the optimum core shape capable of improving the DC superimposition characteristics in the above and achieving miniaturization of the core shape can be realized.</p><p> That is, in order to achieve the above object, the reactor component of the present invention includes at least a winding and a magnetic core, and the core includes a winding portion around which the winding is wound and a winding portion around which the winding is wound. In a reactor component formed by winding the winding around the winding portion, including a non-winding portion that is not wound, the winding portion has a cross-sectional area in a direction orthogonal to the magnetic path of the non-winding portion of the core. It is characterized in that it is made smaller with respect to the cross-sectional area in the direction orthogonal to the magnetic path of the part.</p><p> With such a configuration, it is possible to reduce the size, weight, and cost of the entire reactor by reducing the core shape of the reactor component. Further, it is possible to improve the DC superimposition characteristic in the high current region while reducing the core shape of the reactor component.</p><p> In this case, the cross-sectional area in the direction orthogonal to the magnetic path of the non-winding portion of the core is made smaller than the cross-sectional area in the direction orthogonal to the magnetic path of the winding portion, so that the non-winding portion Is considered to be magnetically saturated before the winding portion, and as a result, the DC superimposition characteristic in the high current region is considered to be improved.</p><p> Further, the cross-sectional area of the non-wound portion can be increased to about 0.76 times to about 0.67 times the cross-sectional area of the wound portion. With such a configuration, it is possible to reduce the size, weight, and cost of the core as a reactor component and thus the reactor, and to improve the DC superimposition characteristic in a high current region.</p><p> Further, the present invention includes at least a winding and a magnetic core, and the core includes a winding portion in which the winding is wound and a non-winding portion in which the winding is not wound. In the reactor component formed by winding the winding around the winding portion, the winding portion has at least two magnetic blocks having a rectangular trapezoidal shape arranged in parallel at intervals, and the non-winding portion is formed. The portion is composed of two magnetic blocks having a substantially trapezoidal or substantially triangular planar shape, which are arranged so as to face each other with the magnetic block constituting the winding portion sandwiched between the bottom sides of the respective substantially trapezoidal or substantially triangular shapes. In addition, the cross-sectional area of the magnetic block constituting the non-winding portion in the direction orthogonal to the magnetic path at the top of the substantially trapezoidal or substantially triangular shape is in the direction orthogonal to the magnetic path of the magnetic block constituting the winding portion. It is characterized in that it is made smaller than the cross-sectional area. According to such a configuration, the volume of each magnetic block itself constituting the non-winding portion can be made smaller than in the case where the non-winding portion is formed of a U-shaped or rectangular magnetic material block. .. Therefore, it is possible to further reduce the size, weight, and cost of the core as a reactor component and thus the reactor.</p><p> The core may be configured as an 8-split type including a magnetic gap. With such a configuration, the improvement of the DC superimposition characteristic according to the reduction amount of the cross-sectional area of the non-wound portion becomes remarkable.</p><p> Further, the reactor component of the present invention is preferably used for an in-vehicle reactor. When a vehicle accident or the like occurs, the circuit may break down and a large current may flow through the vehicle-mounted reactor. Therefore, by using the reactor component of the present invention for the vehicle-mounted reactor, a high inductance value can be obtained in a high current region. Since it is obtained, safety can be improved.</p>

The reactor component according to the first embodiment of the present invention will be described in detail with reference to the drawings. FIG. 2 is a perspective view of a reactor as an example including the reactor component of the present embodiment.

The reactor 10 shown in FIG. 2 is used, for example, in an electric circuit of a device having a forced cooling means, and is formed by winding a winding 2 around a bobbin 4 and inserting a core 109 (see FIG. 4) described later into the bobbin 4. After the reactor parts are housed in the heat conductive case 1, the filler 8 is poured and fixed. The lead portion 5 has the coating of the winding 2 peeled off to expose the conductor, and a crimp terminal or the like (not shown) is provided to connect the lead portion 5 to other electric parts or the like. The notch 12 for the lead portion of the heat conductive case 1 is formed so that the lead portion 5 and the heat conductive case 1 do not interfere with each other. Since the heat conductive case 1 is generally made of metal, the lead portion is formed. An insulator is inserted in the notch 12 for the lead portion in order to insulate 5 from the heat conductive case 1. The reactor fixing holes 13 at the four corners of the heat conductive case 1 are screw holes for fixing the heat conductive case 1 to, for example, a forcedly cooled housing.

FIG. 3 is an exploded perspective view of the reactor shown in FIG. As shown in FIG. 3, the heat conductive case 1 includes a heat conductive case bottom surface 11 and a heat conductive case bottom surface 14 which is shallower than the heat conductive case bottom surface 11 and is formed with a step. The reactor in Fig. 2 is a reactor component formed by laying an insulating sheet 7 on the bottom surface 11 of the thermal conductive case, winding the winding 2 around the bobbin 4, and inserting the core 109 (see Fig. 4 for details) into the bobbin 4. It is stored. After storage, the bottom surface 11 of the heat conductive case comes into contact with the back surface of the winding 2 of the reactor component (not shown) via the insulating sheet 7, and the bottom surface 14 of the heat conductive case comes into contact with the back surface of the block of the core 109. The insulating sheet 7 is inserted between the bottom surface 11 of the thermal conductive case and the winding 2 in order to electrically insulate the thermal conductive case 1 and the winding 2. After storage, the filler 8 is poured and the reactor component is fixed to the thermal conductive case 1.

4A and 4B are views showing the shape of the core 109 of the reactor component of the present embodiment, in which FIG. 4A is a plan view thereof and FIG. 4B is a side view thereof. As shown in FIGS. 4A and 4B, the core 109 of the reactor component of the present embodiment has two magnetic block 103a and six magnetic blocks 103b as a magnetic gap between each block. It is formed from the sheet material 106 to be inserted. That is, in the present embodiment, in the core 109, the six magnetic block 103b constituting the winding portion around which the winding 2 (see FIGS. 2 and 3) is wound, and the winding 2 are not wound. It contains two magnetic blocks 103a that make up the non-winding part, and is wound around the six magnetic blocks 103b that make up the winding part via the bobbin 4 shown in FIGS. 2 and 3. Wire 2 is wound to form a reactor component. As shown in FIGS. 4 (a) and 4 (b), the shape of the core 109 of this reactor component is substantially ring-shaped as a whole, and the six magnetic block 103b constituting the winding portion described above is formed. Formed two straight portions each consisting of three magnetic blocks 103b, and the winding 2 was wound around each straight portion via the winding frame portion of the bobbin 4, and predetermined electrical characteristics were obtained. .. The two magnetic blocks 103a constituting the non-winding portion described above are connected to each straight portion composed of the three magnetic blocks 103b, and the core 109 is formed into a substantially ring shape. The sheet material 106 is inserted into the joint portion between the magnetic blocks 103b and the joint portion between the magnetic block 103a and the magnetic block 103b for a magnetic gap.

By the way, in the core 109 of this reactor component, as shown in FIGS. 4 (a) and 4 (b), the magnetic block 103b has a uniform core cross-sectional area, but the magnetic block 103a is a magnetic material. Does not have a uniform core cross-sectional area with respect to block 103b. That is, in the design of the core of the reactor component, the magnetic path was designed with the same cross-sectional shape in the core 9 of the conventional reactor component shown in FIG. 1, but in the core 109 of the reactor component of the present embodiment, each magnetism is used. The portion of the body block 103a through which magnetic flux hardly passes is reduced, and the cross-sectional area of the two magnetic block 103a constituting the non-winding portion of the core 109 in the direction orthogonal to the magnetic path is set as the winding portion. It was made smaller than the cross-sectional area of each of the constituent magnetic block 103b in the direction orthogonal to the magnetic path.

Here, the dimensions of the blocks of each magnetic material forming the core 109 in the present embodiment will be described. The block 103b of each magnetic material was formed to have a core (block) width Wb of 27.0 mm and a block length Lb of 16.5 mm as shown in FIG. 4 (a). On the other hand, in the magnetic block 103a, the block length La shown in FIG. 4A was 72.0 mm, and the core (block) width W1a was formed within the range of 20.5 mm to 18.0 mm. Further, as shown in FIG. 4B, the height Ha of the magnetic block 103a and the height Hb of the magnetic block 103b are both 27.5 mm and are formed to have the same dimensions. Therefore, the cross-sectional area Wb * Hb in the direction orthogonal to the magnetic path of the magnetic block 103b constituting the winding portion where the winding is wound is 742.5 mm2, whereas the winding is not wound. The cross-sectional area W1a * Ha of the magnetic block 103a constituting the coil is 563.75 mm2 to 495.0 mm. Therefore, the cross-sectional area W1a * Ha in the direction orthogonal to the magnetic path of the magnetic block 103a constituting the non-winding portion is the cross-sectional area in the direction orthogonal to the magnetic path of the magnetic block 103b constituting the wound portion. It remains at about 76% to about 67% (about 0.76 times to about 0.67 times) of Wb * Hb. In other words, the cross-sectional area W1a * Ha of the magnetic block 103a constituting the non-winding portion is about 24% to about 33% smaller than the cross-sectional area Wb * Hb of the magnetic block 103b constituting the winding portion. are doing. As shown in FIGS. 4A and 4B, the magnetic block 103a has a cross-sectional area W1a because the main part of the magnetic block 103a is formed with a cross-sectional area W1a * Ha, except for both corners thereof. If * Ha is made smaller, the volume of the magnetic block 103a is greatly reduced. Therefore, by reducing the volumes of the two magnetic blocks 103a, the overall size and cost of the core 109 can be reduced.

The one-dot chain line shown in FIGS. 4A and 4B shows that the core (block) width WCa of the magnetic block 103a is the same as the core (block) width Wb of the magnetic block 103b. When it is set to 27.0 mm, that is, when the cross-sectional area WCa * Ha of the magnetic block 103a constituting the non-winding portion is not smaller than the cross-sectional area Wb * Hb of the magnetic block 103b constituting the wound portion. The core shape of. Further, the dotted lines in FIGS. 4 (a) and 4 (b) indicate the core shape in the second embodiment of the present invention, which will be described later, in which the core (block) width W2a of the magnetic block 103a is further reduced. Is.

In FIG. 5, as described above, the core (block) width W1a of the magnetic block 103a is changed within the range of 20.5 mm to 18.0 mm to form a reactor component including the core 109, and the reactor including the reactor component is formed. The inductance value (μH) for each current value (A) was measured and summarized in the table. As a comparative example, the same measurement was performed when the core (block) width WCa of the magnetic block 103a was set to 27.0 mm, which is the same as the core (block) width Wb of the magnetic block 103b, as in the conventional example. Indicates a value. In addition, FIG. 6 shows a graph showing these relationships.

In FIGS. 5 and 6, the core (block) width W1a of the magnetic block 103a shown in FIG. 4 is 20.5 mm (Example 1), 20.0 mm (Example 2), and 19.5 mm (Example 3). , 19.0 mm (Example 4), 18.5 mm (Example 5), 18.0 mm (Example 6), and so on, a reactor using a core 109 changed in 0.5 mm increments within the range of 20.5 mm to 18.0 mm. For the reactor including the parts, each inductance value (μH) is shown for each current value in 14 steps from 0 (A) to 450 (A).

In particular, as is clear from the graph of FIG. 6, for all core (block) width cases from Example 1 to Example 6, for current values in the range 0 (A) to 160 (A). Each inductance value (μH) shows a value of around 250 (μH), which is substantially the same as the case of the comparative example. Therefore, if the core (block) width W1a is reduced within the range of 20.5 mm to 18.0 mm as in the present embodiment, in the relatively low current region from 50 (A) to 160 (A). If no reduction is made, a high inductance value can be obtained as in [when the core (block) width WCa is 27.0 mm]. As a result, if the core (block) width W1a is reduced within the range of 20.5 mm to 18.0 mm as in the present embodiment, the comparison from 0 (A) to 160 (A) is performed in the same manner as when no reduction is performed. It was confirmed that the function as a reactor can be sufficiently fulfilled in the region of low current.

By the way, as is clear from the graph of FIG. 6, in the case of all the core (block) widths from Example 1 to Example 6, 300 (A) or more [from 300 (A) to 450 (A)]. In the region of relatively high current, each inductance value (μH) shows a value equal to or higher than that of the case of the comparative example. Therefore, if the core (block) width W1a is reduced within the range of 20.5 mm to 18.0 mm as in the present embodiment, it is not reduced at all in the relatively high current region of 300 (A) or more [ When the core (block) width WCa is 27.0 mm] or higher inductance value can be obtained. As a result, if the core (block) width W1a is reduced within the range of 20.5 mm to 18.0 mm as in the present embodiment, it is in a relatively high current region of 300 (A) or more as compared with the case where it is not reduced at all. It was confirmed that the DC superimposition characteristics were significantly improved. That is, it was confirmed that even when a relatively high current of 300 (A) or more flows, the safety as a reactor is further enhanced as compared with the case where no reduction is performed at all. Therefore, by setting the core (block) width W1a within the range of about 0.76 times to about 0.67 times the core (block) width Wb as in the present embodiment, the size and cost of the reactor can be reduced as described above. In addition, it is possible to improve the DC superimposition characteristics in a relatively high current region of 300 (A) or more. In this case, the cross-sectional area W1a * Ha in the direction orthogonal to the magnetic path of the magnetic block 103a constituting the non-winding portion of the core 109 is orthogonal to the magnetic path of the magnetic block 103b constituting the winding portion. By making it smaller than the cross-sectional area Wb * Hb in the direction in which it is applied, it is conceivable that the non-wound portion is magnetically saturated before the wound portion, and as a result, the DC superimposition characteristic in the high current region is improved. It is expected to improve.

For example, when a reactor as in this embodiment is used for in-vehicle use (for controlling the motor current flowing in a hybrid vehicle, etc.), the region of relatively low current from 0 (A) to 160 (A) described above is usually used. Often used as an area of use. In addition, in the event of a vehicle accident, etc., there is a risk that the circuit will break down and a large current will flow momentarily to the in-vehicle inductance, so from the viewpoint of safety, a relatively high current range of 300 (A) or more It is very desirable to obtain a high inductance value in. Therefore, by reducing the core (block) width W1a within the range of 20.5 mm to 18.0 mm as in the present embodiment, it is possible to provide a core as an optimum reactor component for such an in-vehicle reactor.

Next, the reactor component according to the second embodiment of the present invention will be described. The reactor component of the present embodiment and the basic configuration of the reactor including the reactor component are the same as those of the first embodiment shown in FIGS. 2 to 4. Therefore, also in this second embodiment, the core 109 is composed of eight divisions as a whole as in the first embodiment. On the other hand, in the second embodiment, the cross-sectional area in the direction orthogonal to the magnetic path of the non-wound portion of the core 109 described above is made smaller than the cross-sectional area in the direction orthogonal to the magnetic path of the wound portion. It is characterized in that the amount of reduction is further increased as compared with the first embodiment. That is, in the present embodiment, the core (block) width W2a shown in FIG. 4 (a) of the magnetic block 103a is formed within the range of 15.0 mm to 5.0 mm.

As described above, FIG. 7 shows a reactor component including the core 109 formed by changing the core (block) width W2a of the magnetic block 103a within the range of 15.0 mm to 5.0 mm, and the reactor including the reactor component. , The inductance value (μH) for each current value (A) is measured, and the table shows Examples 7, 8 and 9 to be added to Examples 1 to 6 in the above-described first embodiment. It is a summary. Further, the value of the comparative example in which the core (block) width WCa of the magnetic block 103a measured in the first embodiment is 27.0 mm is also shown in the same manner. FIG. 8 is a graph showing these relationships.

In FIGS. 7 and 8, the core (block) width W2a of the magnetic block 103a shown in FIG. 4 is 15.0 mm (Example 7), 10.0 mm (Example 8), 5.0 mm (Example 9). In this way, the current value of each reactor including the reactor component using the core 109 changed in 5 mm increments within the range of 15.0 mm to 5.0 mm has 14 levels of current value from 0 (A) to 450 (A). On the other hand, each inductance value (μH) is shown.

In particular, as is clear from the table of FIG. 7, in the case of the core (block) width of the ninth embodiment in the present embodiment, from 50 (A) which is the driving time except 0 (A) which is the non-driving time. The inductance value (μH) drops immediately. Further, in the case of the core (block) width of Example 8, the inductance value (μH) drops considerably from 130 (A). Further, in the case of the core (block) width of Example 7, the inductance value (μH) drops considerably from 200 (A). On the other hand, as is clear from the graph of FIG. 8, in the case of all the core (block) widths of Example 7, Example 8 and Example 9 in this embodiment, from 300 (A) or more [300 (A)). In the relatively high current region [up to 450 (A)], each inductance value (μH) shows a significantly higher value than the case of the comparative example. Therefore, if the core (block) width W2a is reduced within the range of 15.0 mm to 5.0 mm as in the present embodiment, it is not reduced at all in the relatively high current region of 300 (A) or more [ When the core (block) width WCa is 27.0 mm], a significantly higher inductance value can be obtained. As a result, if the core (block) width W2a is reduced within the range of 15.0 mm to 5.0 mm as in the present embodiment, it is in a relatively high current region of 300 (A) or more as compared with the case where it is not reduced at all. It was confirmed that the DC superimposition characteristics were improved. That is, it was confirmed that even when a relatively high current of 300 (A) or more flows, the safety as a reactor is further enhanced as compared with the case where no reduction is performed at all. Therefore, as in the present embodiment, the core (block) width W2a is about 0.76 times to about 0. By setting the range to 67 times, it is possible to reduce the size and cost of the reactor as described above, and to improve the DC superimposition characteristic in a relatively high current region of 300 (A) or more. Also in this case, the cross-sectional area W2a * Ha in the direction orthogonal to the magnetic path of the magnetic block 103a constituting the non-winding portion of the core 109 is the magnetic path of the magnetic block 103b constituting the winding portion. By making it smaller with respect to the cross-sectional area Wb * Hb in the orthogonal direction, it is conceivable that the non-wound portion is magnetically saturated before the wound portion, and as a result, DC in the high current region. It is considered that the superimposition characteristics are improved.

In the case of the core (block) width of Example 7, a value of 240 (μH) or more is shown in a relatively low current region from 0 (A) to 130 (A). Therefore, if the core (block) width W2a is reduced to 15.0 mm as in Example 7, if it is not reduced at all in the relatively low current region from 0 (A) to 130 (A) [core] (When the width WCa is 27.0 mm] and the case where the width is reduced within the range of 20.5 mm to 18.0 mm as in the first embodiment, a high inductance value can be obtained. Therefore, if the core (block) width W2a is reduced to 15.0 mm as in Example 7, it can sufficiently function as a reactor in a relatively low current region from 0 (A) to 130 (A). I was able to confirm that.

Subsequently, the reactor component according to the third embodiment of the present invention will be described. The reactor component of the present embodiment and the basic configuration of the reactor including the reactor component are shown in FIGS. 9 and 10. FIG. 9 is a plan view showing the shape of the core 119 of the reactor component of the present embodiment, and FIG. 10 is a diagram showing the reactor including the core 119. As shown in FIG. 9, in the third embodiment, unlike the first and second embodiments described above, the core 119 is composed of four divisions as a whole. The core 119 of the reactor component of the present embodiment is formed of two magnetic blocks 113a and two magnetic blocks 113b and a sheet material 116 inserted as a magnetic gap between the blocks. That is, in the present embodiment, the core 119 has two magnetic blocks 113b constituting the winding portion in which the winding 112 shown in FIG. 10 is wound, and a non-winding portion in which the winding 112 is not wound. The winding 112 is wound around the two magnetic blocks 113b constituting the winding portion via a bobbin (not shown) to form a reactor component. However, the predetermined electrical characteristics can be obtained. The sheet material 116 is inserted into the joint portion between the magnetic block 113a and the magnetic block 113b for a magnetic gap.

By the way, in the core 119 of this reactor component, as shown in FIG. 9, the magnetic block 113b has a uniform core cross-sectional area, but the magnetic block 113a is uniform with respect to the magnetic block 113b. Does not have a large core cross-sectional area. That is, in the conventional core, the magnetic path is designed with the same cross-sectional shape, but in the core 119 of the reactor component of the present embodiment, the portion of the block 113a of each magnetic material through which magnetic flux hardly passes is reduced. , The cross-sectional area of the two magnetic blocks 113a constituting the non-winding portion of the core 119 in the direction orthogonal to the magnetic path is orthogonal to the magnetic path of the two magnetic blocks 113b constituting the winding portion. It was made smaller than the cross-sectional area in the direction.

Here, in the present embodiment, the core (block) width W3b of the magnetic block 113b is 15.0 mm, whereas the core (block) width W3a of the magnetic block 113a is the same 15.0 mm to 12.5 mm. It was formed by reducing it to 10.0 mm. Although not shown in FIG. 9, the height H3a of the magnetic block 113a and the height H3b of the magnetic block 113b have the same dimensions. Therefore, with respect to the cross-sectional area W3b * H3b in the direction orthogonal to the magnetic path of the magnetic block 113b that constitutes the winding portion around which the winding is wound, the magnetism that constitutes the non-winding portion where the winding is not wound. The cross-sectional areas W3a * H3a of the body block 113a remain at about 0.83 times and about 0.67 times, respectively. In other words, the cross-sectional area W3a * H3a of the magnetic block 113a constituting the non-winding portion is about 17% and about 33%, respectively, of the cross-sectional area W3b * H3b of the magnetic block 113b constituting the winding portion. % Reduction. Since the magnetic block 113a is formed by the cross-sectional area W3a * H3a in the length direction, if the cross-sectional area W3a * H3a is reduced, the volume of the magnetic block 113a is reduced. .. Therefore, by reducing the volumes of the two magnetic blocks 113a, the overall size and cost of the core 119 can be reduced.

The broken line in FIG. 9 shows the case where the core (block) width W3Ca of the magnetic block 113a is 15.0 mm, which is the same as the core (block) width W3b of the magnetic block 113b, that is, This is the core shape when the cross-sectional area W3Ca * H3a of the magnetic block 113a constituting the non-winding portion is not smaller than the cross-sectional area W3b * H3b of the magnetic block 113b constituting the winding portion.

In FIG. 11, as described above, the core (block) width W3a of the magnetic block 113a is changed to 12.5 mm (Example 10) and 10.0 mm (Example 11) to form a reactor component including the core 119. Regarding the reactor using the reactor parts as shown in Fig. 10, three samples No. 1, No. 2 and No. 3 were prepared, and the inductance value (μH) with respect to the current value (20A) was calculated for each. It is measured and summarized in the table. As a comparative example, the same values measured when the core (block) width W3Ca of the magnetic block 113a is 15.0 mm as in the conventional example are shown.

In FIG. 11, regarding the inductance 110 using the core 119 in which the core (block) width W3a of the magnetic block 113a shown in FIG. 9 is 12.5 mm (Example 10) and 10.0 mm (Example 11). For each of the three samples No. 1, No. 2 and No. 3, the inductance values (μH) were measured under the measurement conditions of 10 KHz, 1 V, and DC20 (A), respectively. As is clear from FIG. 11, in Example 10 in which the core (block) width W3a of the magnetic block 113a is 12.5 mm, each inductance is obtained in all the samples of No. 1, No. 2 and No. 3. The value (μH) shows almost the same value as the case of the comparative example [the inductance value (μH) decreased by 0.4% on the average of the three samples]. Therefore, if the core (block) width W3a is reduced to 12.5 mm as in the present embodiment, the inductance is the same as when the core (block) width W3Ca is 15.0 mm under such conditions. The value is obtained. As a result, it was confirmed that if the core (block) width W3a is reduced to 12.5 mm as in the present embodiment, the function as a reactor shown in FIG. 10 can be sufficiently fulfilled as in the case where the core (block) width W3a is not reduced at all. ..

As in the case of FIG. 11, FIG. 12 shows the reactor component including the core 119 by changing the core (block) width Wa of the magnetic block 113a to 12.5 mm (Example 10) and 10.0 mm (Example 11). When the reactor formed and used as shown in FIG. 10 is driven, (1) between the coils, (2) the coil surface, (3) the upper surface of the reactor, and (4) the periphery are shown in FIG. The table below compares the degree of temperature rise for each of the four temperature points. As a comparative example, the same values measured when the core (block) width W3Ca of the magnetic block 113a is 15.0 mm as in the conventional example are shown.

In FIG. 12, the reactor 110 using the core 119 in which the core (block) width W3a of the magnetic block 113a shown in FIG. 9 is 12.5 mm (Example 10) and 10.0 mm (Example 11) is defined. Regarding the four points of (1) coil spacing, (2) coil surface, (3) reactor upper surface, and (4) ambient temperature when driven under the measurement conditions shown in Fig. 11, each temperature (° C) and when not driven The temperature rise from Δt (° C) was measured. As is clear from FIG. 12, in Example 10 in which the core (block) width W3a of the magnetic block 113a is 12.5 mm, the temperature rise value shows substantially the same value as in the case of the comparative example [average]. It increased by about 1.4% more than the comparative example]. Therefore, if the core (block) width W3a is reduced to 12.5 mm as in the present embodiment, the temperature is the same as when the core (block) width W3Ca is 15.0 mm under such conditions. The characteristics are obtained.

Further, in the same manner as described above, the core (block) width W3a of the magnetic block 113a is changed to 12.5 mm (Example 10) and 10.0 mm (Example 11) to form a reactor component including the core 119, and the reactor thereof is formed. The noise generated when the reactor was driven using the parts as shown in Fig. 10 was measured. As a comparative example, the same noise was measured when the core (block) width W3Ca of the magnetic block 113a was set to 15.0 mm as in the conventional example. FIG. 13 shows the measurement result of the noise data of the comparative example set to 15.0 mm, FIG. 14 shows the measurement result of the noise data of Example 10 set to 12.5 mm, and FIG. 15 shows the noise data of Example 11 set to 10.0 mm. The measurement results are shown respectively.

As can be seen from FIGS. 13 and 14, there is almost no difference in noise in Example 10 with 12.5 mm as compared with the case with 15.0 mm. On the other hand, as can be seen from FIGS. 13 and 15, in Example 11 with 10.0 mm, noise increased in the frequency range of 2 KHz to 6 KHz as compared with the case of 15.0 mm. It's getting a little worse. It is considered that in Example 11 with 10.0 mm, the magnetic flux was concentrated and the noise due to the vibration of the core due to the electromagnetic attraction increased due to the smaller cross-sectional area.

Next, the reactor component according to the fourth embodiment of the present invention will be described. The core configuration of the reactor component of this embodiment is shown in FIGS. 16 to 22, and the magnetic flux distribution state of the corresponding core is shown in FIGS. 23 to 28.

The feature of this embodiment is that, as in the first to third embodiments described above, the winding portion is formed by arranging magnetic blocks having at least two rectangular trapezoidal shapes in parallel at intervals. In the non-winding portion, two magnetic block having a substantially trapezoidal or substantially triangular planar shape are arranged so as to face each other with the magnetic block constituting the winding portion sandwiched between the bottom side of each substantially trapezoid or the substantially triangular shape. The cross-sectional area of the magnetic block forming the non-winding portion in the direction orthogonal to the magnetic path at the top of the substantially trapezoidal or substantially triangular shape is in the direction orthogonal to the magnetic path of the magnetic block forming the winding portion. It is characterized in that it is made smaller than the cross-sectional area. According to this configuration, the volume of each magnetic block itself constituting the non-winding portion is made smaller than that in the case where the non-winding portion is formed of a U-shaped magnetic block or a rectangular magnetic block. be able to. Therefore, it is possible to further reduce the size, weight, and cost of the core as a reactor component and thus the reactor.

In this fourth embodiment as well, conventionally, it has been generally practiced to design a magnetic path having the same cross-sectional shape, but by reducing the portion through which almost no magnetic flux passes, direct current in a high current region is achieved. The essence of the invention is to optimize the core shape that can achieve miniaturization while ensuring the superimposition characteristics, and it is based on the same technical idea as in the first to third embodiments.

That is, in the first embodiment and the first to fifth embodiments of the fourth embodiment, the windings 2 (see FIGS. 2 and 3) and 112 (see FIGS. 2 and 3) and 112 (see FIGS. 2 and 3) are also used in the same manner as in the first to third embodiments described above. 10) is not wound The width Wa of each of the two magnetic blocks 123a that make up the non-winding part is reduced to be narrower than the width Wb of each magnetic block 123b that makes up the winding part. By doing so, the cross-sectional area of the two magnetic blocks 123a constituting the non-winding portion of the core 129 in the direction orthogonal to the magnetic path is the magnetic path of the two magnetic blocks 123b constituting the winding portion. It is made smaller than the cross-sectional area in the direction orthogonal to. However, in the first embodiment and the first to fifth embodiments of the fourth embodiment, unlike the first to third embodiments, the two magnetic blocks 123a constituting the non-winding portion are each of the second magnetic block 123a. It is formed by a magnetic block having a substantially trapezoidal or substantially triangular planar shape, instead of a U-shaped magnetic block as in the first and second embodiments or a rectangular magnetic block as in the third embodiment. , The magnetic block 123a that constitutes the non-winding part is formed by arranging the two magnetic blocks 123b that form the winding part on the bottom side of each substantially trapezoidal shape or the substantially triangular shape so as to face each other. The cross-sectional area at the top of the substantially trapezoidal or substantially triangular shape in the direction orthogonal to the magnetic path is made smaller than the cross-sectional area in the direction orthogonal to the magnetic path of the magnetic block 123b constituting the winding portion.

With this configuration, as compared with the case where the non-winding portion is formed of a U-shaped magnetic block or a rectangular magnetic block, even if the overall length of the core 129 is the same, each of the non-winding portions constitutes the non-winding portion. The volume of the magnetic block 123a itself can be made smaller. Therefore, it is possible to further reduce the size, weight, and cost of the core as a reactor component and thus the reactor.

When compared with the first and second embodiments described above, this embodiment has both corners (round) of the two U-shaped magnetic block 103a in the first and second embodiments described above. Since the relationship is the same as when the trapezoidal corners) are cut so as to be flat, the optimum values such as the core width of the non-winding portion in the first and second embodiments described above are used as they are. (In other words, the height of the substantially trapezoidal or substantially triangular shape [the core width at the top of the substantially trapezoidal or approximately triangular shape] is designed to this optimum value).

From the viewpoint of optimizing the core shape that can achieve miniaturization by reducing the portion through which the magnetic flux hardly passes as described above, the present inventor of the first embodiment shows the first embodiment shown in FIG. In addition, the cores of the reactor parts according to the modified examples 1 to 5 in which the dimension Wm shown in Fig. (A) is changed are designed, the magnetic flux distribution state of each is observed by simulation, and each magnetism constituting the non-winding portion The optimum shape of the body block 123a in a substantially trapezoidal shape or a substantially triangular shape was sought.

First, the configuration of the core of the reactor component of the first embodiment of the present embodiment will be described in detail. 16A and 16B are views showing the shape of the core of the reactor component according to the first embodiment of the fourth embodiment of the present invention, in which FIG. 16A is a plan view thereof and FIG. 16B is a perspective view thereof. As shown in FIGS. 16A and 16B, the core of the reactor component of the first embodiment of the present embodiment is composed of the core 129 divided into eight parts as a whole. The core 129 of the reactor component of the present embodiment is formed of two magnetic blocks 123a and six magnetic blocks 123b and a sheet material (not shown) inserted as a magnetic gap between the blocks. There is. Then, the non-winding portion in which the winding 2 is not wound is composed of two magnetic material blocks 123a having a substantially trapezoidal planar shape, and three magnetic materials each constituting the winding portion on the bottom side of the substantially trapezoidal shape. Magnetic material that constitutes the non-winding portion by arranging them so as to face each other with the block 123b in between. It is made smaller than the cross-sectional area of block 123b in the direction orthogonal to the magnetic path.

The shape of the core 129 of this reactor component is substantially ring-shaped as a whole, but the shape is such that the four round portions of the ring are cut into a flat shape, which constitutes the winding portion 6 described above. Each of the three magnetic block 123b forms two straight portions consisting of three magnetic block 123b, and each straight portion is wound through the bobbin 4 winding frame portion as shown in FIG. The wire 2 is wound to obtain a predetermined electrical characteristic.

Here, the dimensions of the blocks of each magnetic material forming the core 129 in the first embodiment of the present embodiment will be described. The block 123b of each magnetic material was formed to have a core (block) width Wb of 27.0 mm and a block length Lb of 16.5 mm as shown in FIG. 16 (a). On the other hand, the magnetic block 123a has a block length La of 72.0 mm and a core (block) width Wa of a substantially trapezoidal top (top) of 18.0 mm as shown in FIG. 16 (a). Further, the height Ha of the magnetic block 123a and the height Hb of the magnetic block 123b shown in FIG. 16B are both 27.5 mm and are formed to have the same dimensions.

As described above, in the first embodiment of the fourth embodiment, the cross-sectional area Wb * Hb in the direction orthogonal to the magnetic path of the magnetic block 123b constituting the winding portion around which the winding is wound is 742.5 mm.²On the other hand, the cross-sectional area Wa * Ha at the substantially trapezoidal top (top) of the magnetic block 123a that constitutes the non-winding part where the winding is not wound is 495.0 mm.²Is. As described above, also in the first embodiment, the cross-sectional area in the direction orthogonal to the magnetic path of the non-wound portion of the core is orthogonal to the magnetic path of the wound portion, as in the first to third embodiments described above. It is made smaller than the cross-sectional area in the direction of Specifically, as in the sixth embodiment of the first embodiment, the cross-sectional area Wa * Ha in the direction orthogonal to the magnetic path of the magnetic block 123a constituting the non-winding portion constitutes the winding portion. It remains at about 67% (about 0.67 times) of the cross-sectional area Wb * Hb in the direction orthogonal to the magnetic path of the magnetic block 123b. In other words, the cross-sectional area Wa * Ha of the magnetic block 123a constituting the non-winding portion is made smaller than the cross-sectional area Wb * Hb of the magnetic block 123b constituting the wound portion by about 33%.

Further, in the first embodiment of the fourth embodiment, as shown in FIGS. 16A and 16B, each magnetic block 123a constituting the non-winding portion is formed in a substantially trapezoidal shape. , Above cross-sectional area Wa * Ha (495.0mm)²) Is the cross-sectional area at the top (top) of the substantially trapezoidal shape, and the cross-sectional area at this top (top) is the cross-sectional area Wb * in the direction orthogonal to the magnetic path of the magnetic block 123b constituting the winding portion. Hb (742.5mm²) Is smaller than. Since each magnetic block 123a constituting the non-winding portion is formed in a substantially trapezoidal shape in this way, the volume of each magnetic block 123a is the first implementation using the U-shaped magnetic block. It is further reduced by about 30% as compared with Example 6 of the embodiment. Therefore, as a result of significantly reducing the volume of the block 123a of each magnetic material, further miniaturization and cost reduction of the entire core 129 are achieved. In FIG. 16A, the dimensional ratios of Wa, Wb, Wn, and Wm are formed so as to be Wa = Wb × 2/3 (about 0.67), Wn = Wa (constant), and Wm = Wb. There is. That is, in this Example 1, it is formed so that Wm = Wb, and the dimension Wm as a parameter is the same as Wb, which is the core width of the magnetic block 123b constituting the winding portion (Wm = Wb). It is set to × 1).

Here, in comparison with the sixth embodiment of the first embodiment using the U-shaped magnetic block, the core 129 of the reactor component of the first embodiment of the present embodiment hardly allows magnetic flux to pass through. In order to reduce the number of parts, the cross-sectional area at the top of the block 123a of the two magnetic materials that make up the non-winding part of the winding is the cross-sectional area of the two magnetic materials that make up the winding part. It is the same that it is made smaller with respect to the cross-sectional area of the block 123b in the direction orthogonal to the magnetic path, but further, in the sixth embodiment of the first embodiment described above, both corners of the two magnetic materials in the block 103a are formed. It has the same relationship as reducing the round shape by cutting the round portion into a flat shape. That is, since it was confirmed that the rounded corners of the two magnetic blocks 103a in the sixth embodiment of the first embodiment are also portions through which magnetic flux hardly passes, the rounded corners of the two magnetic blocks are flat. We devised a core shape similar to the one cut into a shape and reduced it, and found that each magnetic block 123a constituting the non-winding portion was formed into a substantially trapezoidal shape as such a core shape.

FIG. 17 (a) is a diagram in which the magnetic flux distribution state of the core of the reactor component of Example 6 of the first embodiment is observed by simulation, and FIG. 17 (b) is a diagram of the embodiment of the fourth embodiment. It is the figure which observed the magnetic flux distribution state of the core of the reactor component of 1 by simulation. As shown in FIG. 17 (a), it can be confirmed that the rounded corners of the two magnetic blocks 103a in the sixth embodiment of the first embodiment are portions through which magnetic flux hardly passes. Then, as shown in FIG. 17 (b), by forming each magnetic block 123a constituting the non-winding portion with a magnetic block having a substantially trapezoidal planar shape, these round-shaped both corner portions are planarized. The relationship is the same as that of cutting to reduce the volume, and it is possible to further reduce the part where magnetic flux hardly passes, and for each of the two magnetic blocks 123a, the volume corresponding to these cut parts is further increased. It is possible to reduce it. As a result, it is possible to further reduce the size, weight, and cost of the entire core 129 of the reactor component as compared with the sixth embodiment of the first embodiment.

As described above, in the present embodiment, in addition to the first embodiment shown in FIG. 16, the present inventor has used the cores of the reactor parts according to the modified examples 1 to 5 in which the dimension Wm shown in the figure (a) is changed. We also designed and observed each magnetic flux distribution state by simulation, and tried to find the optimum shape of the block 123a of each magnetic material constituting the non-winding part in the substantially trapezoidal shape or the substantially triangular shape. The configuration of the core of the reactor component according to these modified examples 1 to 5 will be described below.

First, the core of the reactor component according to the first modification will be described. In the core of the reactor component according to this modification 1, the wound portion is formed by arranging magnetic blocks having six rectangular planar shapes in parallel at intervals, but the non-wound portion has two substantially trapezoidal shapes. The magnetic block having the plane shape of is arranged so as to face each other with the magnetic block constituting the winding portion sandwiched between the bottom side of each substantially trapezoid, and the magnetic block forming the non-winding portion. The point that the cross-sectional area at the top of the substantially trapezoid in the direction orthogonal to the magnetic path is made smaller than the cross-sectional area in the direction perpendicular to the magnetic path of the magnetic block constituting the winding portion is described in Example 1 described above. Similar to the core according to the above, but the trapezoidal shape of the magnetic block constituting the non-winding portion is formed in a shape different from that of the first embodiment.

That is, in the modified example 1 of the fourth embodiment, as shown in FIGS. 18 (a) and 18 (b), each of the two magnetic material blocks 123a has a top (top) of the two magnetic block 123a as compared with the first embodiment. It is formed so as to have a large size. Specifically, in FIG. 18 (a), the dimensional ratios of Wa, Wb, Wn, and Wm are Wa = Wb × 2/3 (about 0.67), Wn = Wa (constant), and Wm = Wb × 0.25. It is formed like this. That is, in this modification 1, it is formed so that Wm = Wb × 0.25, and the dimension Wm as a parameter is 1/4 of Wb, which is the core width of the magnetic block 123b constituting the winding portion. Is set to.

As described above, even in the core 129 of the reactor component of the present modification 1, the winding portion has a cross-sectional area in the direction orthogonal to the magnetic path at the top of the two magnetic block 123a constituting the non-winding portion of the winding. In addition to making the block 123b smaller than the cross-sectional area in the direction orthogonal to the magnetic path of the two magnetic material blocks constituting the above, in the sixth embodiment of the first embodiment described above, the two magnetic material blocks are further formed. It has the same relationship as reducing the fact that both corners in 103a were formed in a round shape by cutting the round portion in a flat shape. Therefore, it is possible to further reduce the volume corresponding to these cut portions for each of the two magnetic blocks 123a. As a result, it is possible to further reduce the size, weight, and cost of the entire core 129 of the reactor component as compared with the sixth embodiment of the first embodiment.

Next, the core of the reactor component according to the second modification will be described. In the core of the reactor component according to this modification 2, the wound portion is formed by arranging magnetic blocks having six rectangular planar shapes in parallel at intervals, but the non-wound portion is two substantially trapezoidal shapes. The magnetic block having the planar shape of is arranged so as to face each other with the magnetic block constituting the winding portion sandwiched between the bottom sides of the respective substantially trapezoids, and the magnetic block forming the non-winding portion. The point that the cross-sectional area at the top of the substantially trapezoid in the direction orthogonal to the magnetic path is made smaller than the cross-sectional area in the direction perpendicular to the magnetic path of the magnetic block constituting the winding portion is described in Example 1 described above. Similar to the core according to the above, but the trapezoidal shape of the magnetic block constituting the non-winding portion is formed in a shape different from that of the first embodiment and the first modification.

That is, in the second modification of the fourth embodiment, as shown in FIGS. 19A and 19B, each of the two magnetic block 123a has the dimension of the apex (top) of the embodiment. It is formed so as to be larger than 1 but smaller than the modified example 1. Specifically, in FIG. 19 (a), the dimensional ratios of Wa, Wb, Wn, and Wm are Wa = Wb × 2/3 (about 0.67), Wn = Wa (constant), and Wm = Wb × 0.5. It is formed like this. That is, in this modification 1, it is formed so that Wm = Wb × 0.5, and the dimension Wm as a parameter is 1/2 of Wb, which is the core width of the magnetic block 123b constituting the winding portion. Is set to.

As described above, even in the core 129 of the reactor component of the second modification, the winding portion has a cross-sectional area in the direction orthogonal to the magnetic path at the top of the two magnetic block 123a constituting the non-winding portion of the winding. In addition to making the block 123b smaller than the cross-sectional area in the direction orthogonal to the magnetic path of the two magnetic material blocks constituting the above, in the sixth embodiment of the first embodiment described above, the two magnetic material blocks are further formed. It has the same relationship as reducing the fact that both corners in 103a were formed in a round shape by cutting the round portion in a flat shape. Therefore, it is possible to further reduce the volume corresponding to these cut portions for each of the two magnetic blocks 123a. As a result, it is possible to further reduce the size, weight, and cost of the entire core 129 of the reactor component as compared with the sixth embodiment of the first embodiment.

Next, the core of the reactor component according to the modified example 3 will be described. In the core of the reactor component according to the third modification, the wound portion is formed by arranging magnetic blocks having six rectangular planar shapes in parallel at intervals, but the non-winded portion has two substantially trapezoidal shapes. The magnetic block having the plane shape of is arranged so as to face each other with the magnetic block constituting the winding portion sandwiched between the bottom side of each substantially trapezoid, and the magnetic block forming the non-winding portion. The point that the cross-sectional area at the top of the substantially trapezoid in the direction orthogonal to the magnetic path is made smaller than the cross-sectional area in the direction perpendicular to the magnetic path of the magnetic block constituting the winding portion is described in Example 1 described above. The same as the core according to the above, but the trapezoidal shape of the magnetic block constituting the non-winding portion is formed in a shape different from that of the first embodiment and the first and second modifications.

That is, in the third modification of the fourth embodiment, as shown in FIGS. 20 (a) and 20 (b), each of the two magnetic block 123a has the dimension of the apex (top) of the embodiment. It is formed so as to be larger than 1 but smaller than the modified example 2. Specifically, in FIG. 20 (a), the dimensional ratios of Wa, Wb, Wn, and Wm are Wa = Wb × 2/3 (about 0.67), Wn = Wa (constant), and Wm = Wb × 0.75. It is formed like this. That is, in this modification 1, it is formed so that Wm = Wb × 0.75, and the dimension Wm as a parameter is 3/4 of Wb, which is the core width of the magnetic block 123b constituting the winding portion. Is set to.

As described above, even in the core 129 of the reactor component of the third modification, the winding portion has a cross-sectional area in the direction orthogonal to the magnetic path at the top of the two magnetic block 123a constituting the non-winding portion of the winding. In addition to making the block 123b smaller than the cross-sectional area in the direction orthogonal to the magnetic path of the two magnetic material blocks constituting the above, in the sixth embodiment of the first embodiment described above, the two magnetic material blocks are further formed. It has the same relationship as reducing the fact that both corners in 103a were formed in a round shape by cutting the round portion in a flat shape. Therefore, it is possible to further reduce the volume corresponding to these cut portions for each of the two magnetic blocks 123a. As a result, it is possible to further reduce the size, weight, and cost of the entire core 129 of the reactor component as compared with the sixth embodiment of the first embodiment.

Next, the core of the reactor component according to the modified example 4 will be described. In the core of the reactor component according to this modification 4, the wound portion is composed of six magnetic blocks having a rectangular planar shape arranged in parallel with an interval, but the non-wound portion is two substantially trapezoidal shapes. The magnetic block having the plane shape of is arranged so as to face each other with the magnetic block constituting the winding portion sandwiched between the bottom side of each substantially trapezoid, and the magnetic block forming the non-winding portion. The point that the cross-sectional area at the top of the substantially trapezoid in the direction orthogonal to the magnetic path is made smaller than the cross-sectional area in the direction perpendicular to the magnetic path of the magnetic block constituting the winding portion is described in Example 1 described above. Similar to the core according to the above, but the trapezoidal shape of the magnetic block constituting the non-winding portion is formed in a shape different from that of the first embodiment and the first to third modifications.

That is, in the modified example 4 of the fourth embodiment, as shown in FIGS. 21 (a) and 21 (b), each of the two magnetic block 123a has the dimension of the apex (top) of the embodiment. It is formed so as to be smaller than 1. Specifically, in FIG. 21 (a), the dimensional ratios of Wa, Wb, Wn, and Wm are Wa = Wb × 2/3 (about 0.67), Wn = Wa (constant), and Wm = Wb × 1.25. It is formed like this. That is, in this modification 4, it is formed so that Wm = Wb × 1.25, and the dimension Wm as a parameter is 5/4 of Wb, which is the core width of the magnetic block 123b constituting the winding portion. Is set to.

As described above, even in the core 129 of the reactor component of the present modification 4, the winding portion has a cross-sectional area in the direction orthogonal to the magnetic path at the top of the two magnetic block 123a constituting the non-winding portion of the winding. In addition to making the block 123b smaller than the cross-sectional area in the direction orthogonal to the magnetic path of the two magnetic material blocks constituting the above, in the sixth embodiment of the first embodiment described above, the two magnetic material blocks are further formed. It has the same relationship as reducing the fact that both corners in 103a were formed in a round shape by cutting the round portion in a flat shape. Therefore, it is possible to further reduce the volume corresponding to these cut portions for each of the two magnetic block 123a. As a result, it is possible to further reduce the size, weight, and cost of the entire core 129 of the reactor component as compared with the sixth embodiment of the first embodiment.

Further, the core of the reactor component according to the modified example 5 will be described. In the core of the reactor component according to this modification 5, the wound portion consists of six magnetic blocks having a rectangular planar shape arranged in parallel at intervals, but the non-wound portion has two substantially triangular shapes. The magnetic block having the planar shape of is arranged so as to face each other with the magnetic block constituting the winding portion sandwiched between the bottom sides of the respective substantially triangular triangles, and the magnetic block forming the non-winding portion. The cross-sectional area at the top of the substantially triangle in the direction orthogonal to the magnetic path is made smaller than the cross-sectional area in the direction orthogonal to the magnetic path of the magnetic block constituting the winding portion. That is, the shape of the magnetic block constituting the non-winding portion is different from the trapezoidal shape of the first embodiment and the first to fourth modifications, and is formed in a triangular shape.

Therefore, in the modified example 5 of the fourth embodiment, as shown in FIGS. 22 (a) and 22 (b), each of the two magnetic block 123a has its apex forming a triangular apex. There is. Specifically, in FIG. 22 (a), the dimensional ratios of Wa, Wb, Wn, and Wm are Wa = Wb × 2/3 (about 0.67), Wn = Wa (constant), and Wm = Wb × 1.425. It is formed like this. That is, in this modification 5, it is formed so that Wm = Wb × 1.425, and the dimension Wm as a parameter is 57/40 of Wb, which is the core width of the magnetic block 123b constituting the winding portion. Is set to.

As described above, even in the core 129 of the reactor component of the present modification 5, the winding portion has a cross-sectional area in the direction orthogonal to the magnetic path at the top of the two magnetic block 123a constituting the non-winding portion of the winding. In addition to making the block 123b smaller than the cross-sectional area in the direction orthogonal to the magnetic path of the two magnetic material blocks constituting the above, in the sixth embodiment of the first embodiment described above, the two magnetic material blocks are further formed. It has the same relationship as reducing the fact that both corners in 103a were formed in a round shape by cutting the round portion in a plane shape on two sides other than the base of the triangle. Therefore, it is possible to further reduce the volume corresponding to these cut portions for each of the two magnetic blocks 123a. As a result, it is possible to further reduce the size, weight, and cost of the entire core 129 of the reactor component as compared with the sixth embodiment of the first embodiment. In addition, in this modification 5, as described above, it was formed so that Wm = Wb × 1.425, but the numerical value regarding the ratio of Wm and Wb is a numerical value as an example, and if the coil width or the like changes, Of course, the numerical value (core shape) of 1.425 also changes.

In the first embodiment and the first to fifth embodiments described above, the amount of reduction of the cut and reduced portion as compared with the sixth embodiment of the first embodiment is as shown in FIGS. 16 to 22. As is clear, the amount of reduction in Example 1, Modified Example 4 and Modified Example 5 is relatively large. Therefore, in the first embodiment, the fourth modification, and the fifth modification, the volume of the two magnetic block 123a can be significantly reduced, and the core 129 of the reactor component can be further miniaturized and reduced in cost. It is advantageous in terms of conversion.

On the other hand, in FIGS. 23 to 28, as described above, in the present embodiment, the cores of the reactor parts according to the first embodiment and the modified examples 1 to 5 in which the dimension Wm as a parameter is changed are designed, and the respective magnetic fluxes are shown. As a result of observing the distribution state by simulation, it is a figure which shows the magnetic flux distribution state of the corresponding core.

In FIGS. 23 to 28, as described above, the dimensions Wm of the magnetic block 123a are Wm = Wb × 1 (Example 1), Wm = Wb × 0.25 (Modification 1), and Wm = Wb × 0.5 (Variation example 1). Reactor parts using core 129 modified as Wm = Wb x 0.75 (Modification 3), Wm = Wb x 1.25 (Transformation 4), Wm = Wb x 1.425 (Modification 5) For the core, the magnetic flux distribution state of the core at the time of rated use is shown by color coding.

In particular, as is clear from FIG. 23, the core of Example 1 shows the most well-balanced magnetic flux distribution state without magnetic saturation. Further, as can be seen from FIGS. 24 to 28, even in the cores of the modified examples 1 to 5, no part where the magnetic saturation has reached the limit is found, and it shows a sufficiently usable magnetic flux distribution state. It could be confirmed.

As described above, according to the fourth embodiment of the present invention, the non-wound portion is formed of two magnetic block having a substantially trapezoidal or substantially triangular planar shape, and the magnetic structure constituting the wound portion is formed. The body blocks are placed opposite to each other with the bottom side of each substantially trapezoidal or approximately triangular shape sandwiched between them, and the cross-sectional area of the two magnetic materials constituting the non-winding portion at the top of the block 123a in the direction orthogonal to the magnetic path. Since the cross-sectional area of the two magnetic blocks 123b constituting the winding portion in the direction orthogonal to the magnetic path is made smaller, almost no magnetic flux passes through as compared with the first to third embodiments described above. It is possible to further reduce the cost, size, and weight by further reducing the number of parts.

In the fourth embodiment of the present invention, if it is a dust core, it is easy to manufacture because it is sufficient to make a substantially trapezoidal or substantially triangular mold, put the powder in it, and pressurize it. Therefore, in terms of cost reduction, the dust core is highly effective. However, in terms of miniaturization and weight reduction, it goes without saying that the same high effect can be obtained with both the dust core and the laminated (lamination) core.

The core of the fourth embodiment of the present invention is also housed and used in the same thermal conductive case 1 as shown in FIG. In this case, in the core of the reactor component of the fourth embodiment of the present invention, since the non-winding portion is formed by a magnetic block having a substantially trapezoidal or substantially triangular planar shape, it is like a U-shaped core. Since there are no rounded corners, the surface pressed against the heat conductive case 1 increases, so heat dissipation is improved. In addition, since there are no rounded corners of the U-shaped core and the corners of the core of the reactor component are formed of a flat surface, dead space in the case is reduced and space efficiency is improved.

The core in the first, second and fourth embodiments described above is configured as an 8-split type including a magnetic gap, and the core in the third embodiment is configured as a 4-split type including a magnetic gap. Is also applicable to undivided integrated cores. Further, of course, it can be applied to a division type core having a number of divisions other than 4 divisions and 8 divisions, such as the conventional 6 division type core shown in FIG. However, from the measurement results of the inductance values in the first and third embodiments, it is possible to increase the amount of reduction in the cross-sectional area in the direction orthogonal to the magnetic path of the non-winding portion of the core as the number of divisions increases. It is thought that it can be done.

Although the present invention has been described above based on the embodiments, the present invention is not limited to the above embodiments, and various modifications can be made without departing from the gist of the claims.

The present invention comprises at least a winding and a magnetic core, which includes a wound portion in which the winding is wound and a non-winding portion in which the winding is not wound, and is wound around the winding portion. It is widely applicable as long as it is a core of a reactor component formed by winding.

<figref num="1">It is a perspective view of the core of the conventional reactor component.</figref><figref num="2">It is a perspective view which shows an example of the reactor using the core of the reactor component which concerns on 1st Embodiment of this invention.</figref><figref num="3">It is an exploded perspective view of the reactor shown in FIG.</figref><figref num="4">It is a figure which shows the shape of the core of the reactor component which concerns on 1st Embodiment of this invention, (a) is the plan view, (b) is the side view.</figref><figref num="5">It is the figure which summarized the measurement result of the inductance value (μH) with respect to each current value (A) about the reactor which changed the core (block) width of the reactor component which concerns on 1st Embodiment of this invention.</figref><figref num="6">It is a graph which shows the measurement result shown in FIG.</figref><figref num="7">It is the figure which summarized the measurement result of the inductance value (μH) with respect to each current value (A) about the reactor which changed the core (block) width of the reactor component which concerns on 2nd Embodiment of this invention.</figref><figref num="8">It is a graph which shows the measurement result shown in FIG.</figref><figref num="9">It is a top view which shows the shape of the core of the reactor component which concerns on 3rd Embodiment of this invention.</figref><figref num="10">It is a figure which shows the reactor including the core shown in FIG.</figref><figref num="11">It is the figure which summarized the measurement result of the inductance value (μH) with respect to each current value (A) about the reactor which changed the core (block) width of the reactor component which concerns on 3rd Embodiment of this invention.</figref><figref num="12">(1) Between coils, (2) Coil surface, (3) Reactor upper surface, (4) when a reactor with a different core (block) width of the reactor component according to the third embodiment of the present invention is driven. It is the figure which summarized the measurement result of the temperature rise about 4 points of the ambient temperature in a table.</figref><figref num="13">As a comparative example with respect to the third embodiment of the present invention, it is a figure which shows the measurement result of the noise data at the time of driving a reactor having a core (block) width of 15.0 mm.</figref><figref num="14">It is a figure which shows the measurement result of the noise data at the time of driving the reactor which made the core (block) width of the reactor component which concerns on 3rd Embodiment of this invention 12.5mm.</figref><figref num="15">It is a figure which shows the measurement result of the noise data at the time of driving the reactor which made the core (block) width of the reactor component which concerns on 3rd Embodiment of this invention 10.0mm.</figref><figref num="16">It is a figure which shows the shape of the core of the reactor component which concerns on 4th Embodiment of this invention, (a) is the plan view, (b) is the perspective view.</figref><figref num="17">(a) is a diagram showing a magnetic flux distribution state of the core of the reactor component according to the sixth embodiment of the first embodiment of the present invention, and (b) is a diagram showing the magnetic flux distribution state of the core of the fourth embodiment of the present invention. It is a figure which shows the magnetic flux distribution state of the core of a reactor component.</figref><figref num="18">It is a figure which shows the shape of the core of the reactor part which concerns on the modification 1 of the 4th Embodiment of this invention, (a) is the plan view, (b) is the perspective view.</figref><figref num="19">It is a figure which shows the shape of the core of the reactor component which concerns on the modification 2 of the 4th Embodiment of this invention, (a) is the plan view, (b) is the perspective view.</figref><figref num="20">It is a figure which shows the shape of the core of the reactor part which concerns on the modification 3 of the 4th Embodiment of this invention, (a) is the plan view, (b) is the perspective view.</figref><figref num="21">It is a figure which shows the shape of the core of the reactor part which concerns on the modification 4 of the 4th Embodiment of this invention, (a) is the plan view, (b) is the perspective view.</figref><figref num="22">It is a figure which shows the shape of the core of the reactor part which concerns on the modification 5 of the 4th Embodiment of this invention, (a) is the plan view, (b) is the perspective view.</figref><figref num="23">It is a figure which shows the magnetic flux distribution state of the core of the reactor component which concerns on Example 1 of 4th Embodiment of this invention.</figref><figref num="24">It is a figure which shows the magnetic flux distribution state of the core of the reactor component which concerns on the modification 1 of the 4th Embodiment of this invention.</figref><figref num="25">It is a figure which shows the magnetic flux distribution state of the core of the reactor component which concerns on the modification 2 of the 4th Embodiment of this invention.</figref><figref num="26">It is a figure which shows the magnetic flux distribution state of the core of the reactor component which concerns on the modification 3 of the 4th Embodiment of this invention.</figref><figref num="27">It is a figure which shows the magnetic flux distribution state of the core of the reactor component which concerns on the modification 4 of the 4th Embodiment of this invention .</figref><figref num="28">It is a figure which shows the magnetic flux distribution state of the core of the reactor component which concerns on modification 5 of the 4th Embodiment of this invention.</figref>

Code description

1 Thermal Conductive Case, 2 Winds, 3a, 3b, 103a, 103b, 113a, 113b, 123a, 123b Magnetic Block, 4 Bobbins, 6, 106 Sheets, 7 Insulation Sheets, 8 Fillers, 10 Reactors, Wa, W1a, W2a, W3a, WCa, W3Ca, Wb core (block) width, Ha, Hb core (block) height, 9,109,119,129 cores