JPH11204355A - Composite reactor, its manufacturing method and power supply - Google Patents

Abstract

(57) [Summary] [PROBLEMS] Used in a harmonic current suppression circuit of a DC power supply,
It is an object of the present invention to provide a composite reactor for obtaining two inductances (for AC and DC) that need to be magnetically free from mutual influence, a method for manufacturing the same, and a power supply device. SOLUTION: First and second iron cores 1 and 3 inserted into first and second coils 2 and 4, respectively, and a third iron core 5 serving as a common magnetic leg are separately provided. And a composite reactor in which another fourth iron core portion 8 is joined to the first to third iron core portions via two core gaps to form an unsaturated closed magnetic circuit. Also, by adjusting the core gap size of each abutting portion, the two unsaturated magnetic circuits are magnetically shielded from each other, and the direction of the magnetic flux flowing through the third iron core portion by the LC resonance action is mutually constant for a certain conduction period. Each iron core part 1, so as to cancel each other out of phase, so that only the minimum magnetic flux flows
A method for manufacturing a composite reactor for assembling and fixing 3, 5, and 8. A power supply that uses a complex reactor and clears the harmonic regulation values.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reactor used for electric / electronic equipment employing an inverter circuit and a DC power supply using the same.

[0002]

2. Description of the Related Art Conventionally, inverter control systems that take advantage of fine-grained output control have been widely used in home electric appliances and the like, and their input current waveforms have been improved to suppress current peak values and improve power factor. A reactor was used to do this.

[0003] In recent years, the circumstances of electrical and electronic equipment in Japan and overseas have further increased the trend of so-called harmonic suppression to further improve the current waveform, and the introduction of chopper circuits has been increasing. An active filter method that mainly takes measures on the electronic circuit, and FIG.
A passive filter system in which two individual reactors shown in FIG. 9 are respectively connected between a rectifying diode bridge and a smoothing capacitor has been adopted.

That is, as shown in FIG. 29, a conventional individual reactor comprises an E-shaped core 102 having a core gap formed in a central magnetic leg, an I-shaped core 101 opposed thereto, a coil 103, Has insulating paper 104 to insulate
It was configured to be attached to electric equipment via the attachment plate 105.

[0005]

In the case of the conventional active filter system, almost complete effect can be expected as a measure for suppressing the harmonic current. However, the cost is high, and a lower cost measure has been desired from the practical point of view. . Therefore, even in the passive filter system which is more cost-effective than the active filter system, the required two inductances can be constituted by two independent reactors, respectively. However, there is a disadvantage that the equipment becomes heavy and the volume increases. I was Even if the two necessary inductances are simply realized as a single reactor, the effect of the mutual inductance is large and the harmonic current suppressing effect is inferior.

An object of the present invention is to solve the above problems and to provide a composite reactor suitable for a passive filter that is less expensive, smaller and lighter than the conventional one, and that suppresses harmonic current, a method of manufacturing the same, and a power supply unit. .

[0007]

A first means of the present invention to achieve this object is to form a first iron core portion in which electromagnetic steel sheets are laminated and a first coil is inserted, and a magnetic steel sheet is laminated. And a bridge core for laminating magnetic steel sheets and forming an unsaturated closed magnetic path in the first and second cores via a predetermined core gap, respectively. Has,
A third core portion in which each magnetic flux generated by the first coil and the second coil flows in a canceling direction with respect to each other for at least a part of a period of each cycle of the commercial power supply; The third core portion is disposed between the bridging core portions via a small core gap smaller than the core gap, and the first, second, and third core portions and the bridging core portion are fixed. They are integrally fixed by means.

[0008] The third means of the present invention is the first means, wherein at least the end faces of the first, second, and third iron cores are respectively fitted in both end faces of the bridging core. This is the butted position.

According to a fourth aspect of the present invention, in the first aspect, the cross-sectional area of the third core is set to 5% or more of the sum of the cross-sectional areas of the first and second cores. Things.

According to a fifth aspect of the present invention, in the first aspect, the minute core gap dimension between the third core portion and the bridging core portion is set to a value between the first core portion and the bridging core portion. 40% or less of the predetermined core gap size and 40% or less of the predetermined core gap size between the second core portion and the bridging core portion.

According to a sixth aspect of the present invention, in the first aspect, the unsaturated magnetic circuit formed by each of the iron cores comprises two magnetic cores.
The two coils are integrally fixed so as to form one of a substantially letter-like shape, a roughly-shaped letter shape, and a substantially cross-shaped letter when viewed in a manner such that the two coils are positioned vertically.

Further, the manufacturing method of the present invention is characterized in that a first iron core formed by laminating electromagnetic steel sheets having a first coil inserted therein, and a first iron core formed by laminating electromagnetic steel sheets having a second coil inserted therein. And a bridging core formed by laminating electromagnetic steel sheets for forming an unsaturated magnetic path on the first and second cores with a predetermined core gap interposed therebetween. A third core portion in which magnetic fluxes of the first coil and the second coil flow in directions offset from each other for at least a part of each cycle of the commercial power supply, and a small core gap having a smaller gap than the predetermined core gap; By arranging the third core portion between the bridging core portions via a bridge, a substantially sun-shaped, eye-shaped or cross-shaped magnetic path is formed, and reactor characteristics such as an inductance value are formed. Press the bridge core while measuring the core gap size. Adjusting the thickness of the gap spacer,
The composite reactor is manufactured by fixing the bridging core with fixing means while maintaining the pressing force when the required characteristics are obtained.

A power supply apparatus according to the present invention is a power supply apparatus for forming a DC power supply by rectifying a single-phase alternating current by using the composite reactor of the first means, wherein a full-wave rectification diode bridge and a smoothing capacitor are provided. A series circuit of a first coil and a diode of the reactor and a series circuit of a second coil and a capacitor of the reactor are used in parallel.

Further, another power supply device of the present invention is a power supply device for rectifying a single-phase AC to form a DC power supply by using the composite reactor of the first means, wherein the power supply device is provided at a stage subsequent to a diode bridge for full-wave rectification. A series circuit including a first coil of the reactor and a smoothing capacitor of the diode; and a second circuit of the reactor.
And a series circuit of a capacitor and a capacitor are connected in parallel.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first means of the present invention is to form two open-shaped unsaturated magnetic paths sharing a third iron core and obtain two integrated inductances. , The man-hours required for assembling the reactor can be greatly reduced compared to the case where two independent reactors are used for a passive filter, and the man-hour for mounting the reactor on equipment is reduced to about half. Has the ability to.

The second means of the present invention is to determine the smaller one of the width dimension and the depth dimension of the magnetic path cross section of each of the first, second and third iron cores as the lamination thickness, thereby obtaining the number of laminated cores. Therefore, there is an effect that the number of man-hours for manufacturing each iron core portion can be reduced.

According to the third means of the present invention, the end faces of the first, second, and third core portions do not protrude beyond the end surfaces of the bridging core portions. (2) Leakage magnetic flux from the third iron core is minimized and kept constant, and has the effect of suppressing variations in reactor characteristics due to core shift during assembly.

According to a fourth aspect of the present invention, in the first aspect, the magnetic path cross-sectional area of the third iron core portion, which is a common magnetic path of the two magnetic circuits constituting the two inductances, is usually set to the first value.
100% of the sum of the cross-sectional areas of the iron core portion and the second iron core portion is required, and if 5% or more is secured, the specified reactor characteristics can be obtained, and the amount of iron core used is greatly reduced, and the size and weight are reduced. Has the effect of being able to

According to a fifth aspect of the present invention, a small core gap size between the third core portion and the bridging core portion is smaller than a core gap between the other core portion and the bridging core portion. By setting, there is an effect that the mutual influence between the two inductances can be suppressed to a level that does not cause a practical problem.

The sixth means of the present invention actually embodies the magnetic path configuration in the first means, and has an effect of improving the assembling method, workability, occupied area, etc. according to the form of the magnetic path. Have.

The manufacturing method of the present invention has an effect of easily adjusting a core gap dimension giving a predetermined reactor characteristic by using an inexpensive core gap spacer having elasticity in a thickness direction.

In the power supply device of the present invention, the Lc resonance current flows through each of the two coils forming the harmonic suppression circuit,
Currents having phases opposite to each other flow in each constant conduction period in one cycle of the power supply. As a result, the magnetic fluxes in the canceling directions merge with each other in the third core at least during a part of each cycle of the commercial power supply, and actually, only a small combined magnetic flux canceling each other flows. .
Therefore, the third iron core only needs to form as many magnetic paths as necessary to allow the combined magnetic flux to flow, and the magnetic flux flowing through the first iron core and the magnetic flux flowing through the second iron core are originally merged. Therefore, when a cross-sectional area which is the sum of the cross-sectional areas of the first core portion and the second core portion is required, the cross-sectional area can be reduced to half or less thereof.

An embodiment of the present invention will be described below with reference to FIGS. (Embodiment 1) Embodiment 1 will be described with reference to FIGS.

In FIG. 1, a first iron core 1 formed by laminating short fence-shaped electromagnetic steel sheets and forming a block by means of welding, protruding welding, bonding or the like is inserted into a coil 2. Similarly, the second iron core 3 and the coil 4 are combined. Third
The iron core portion 5 is formed by laminating short fence-shaped electromagnetic steel sheets. The thus configured ones are arranged in the order of a first core part 1, a third core part 5, a second core part 3, and a gap spacer 6 made of an insulating sheet having elasticity in a thickness direction. The two bridge iron cores 8 formed by laminating trapezoidal electromagnetic steel sheets are put together via 7 so as to form a magnetic path in a shape of a horizontal Japanese character by assembling. First coil 2,
The second coil 4 is used as an independent inductance, and the magnetic flux generated by each of the coils 2 and 4 passes through the core gap secured by the thickness of the gap spacers 6 and 7 at the butting portion of each core. Flows in a U-shaped magnetic path,
Serves as two reactors. The core gap between the third core 5 and the bridging core 8 may be omitted depending on the required reactor characteristics.

Out of the five iron cores 1, 3, 5, and 8 forming a sun-shaped magnetic path, the two iron cores located outside are welded and fixed to each other by the fixing bracket 10, and then the other. A mounting plate 9 for mounting to the device is welded and fixed to the bridging core 8. Thereafter, a varnish impregnation treatment is applied to the entire reactor.

Further, the first coil 2 and the second coil 4 are AC inductances Lc and AC, respectively, in a DC power supply (for example, for an inverter air conditioner) having a harmonic current suppressing circuit as shown in FIGS. Each is connected and functions as a DC inductance Ld. 2 and 3 are generally well known as a power supply circuit provided with a harmonic current suppression circuit, and the operation of the harmonic current suppression will be schematically described using the circuit of FIG. 2 as an example. That is, Lc,
To expand the current conduction angle in the first half by flowing about twice the resonance current frequency of the power supply from the low rise times of the power source voltage by the series resonant circuit C _1, whereas, Ld, the phase a series circuit of the D By causing the delayed current to flow, it contributes to an increase in the conduction angle in the latter half. As a result, the input current I of the power supply device that combines these two currents ic and id can combine a smooth current waveform having a wide current conduction angle, that is, a current waveform that includes only a small amount of harmonic current. FIG. 4 shows an example of the current waveform for reference.

There is no problem in the case where the two inductances Lc and Ld are composed of two independent reactors as in the prior art. However, as in the present invention, the two inductances are integrated into one reactor. If you want to configure
It is important how the coupling between the two inductances can be reduced.

FIG. 5 shows the flows of the magnetic fluxes φA and φB generated by the current ic flowing through the first coil 2. That is, φA indicates the magnetic flux flowing through the closed circuit of the first core part 1, the bridge core part 8, the third core part 5, and the bridge core part 8, and φB
Indicates the magnetic flux flowing through the closed circuit of the iron core part 1, the iron core part 8, the iron core part 3, and the iron core part 8. Then, in order to reduce the mutual coupling between the two inductances, it is necessary to eliminate or minimize this φB. In the present invention, in order to realize this, the first core portion 1, the second core portion 3, and the third
The core gap size of the iron core part 5 is set as follows. That is, most of the core gap size necessary for obtaining the inductance characteristic of the inductance Lc is formed between the first core portion 1 and the two bridging core portions 8 (1.5 mm in this embodiment), The core gap between the third iron core portion 5 and the bridging iron core 8, which are common magnetic legs, was almost eliminated (0 to 0.35 mm). Further, most of the core gap size necessary for obtaining the inductance characteristic of the inductance Ld is formed between the second core 3 and the two bridging cores 8 (1.5 mm in this embodiment). .

As a result, the magnetic resistance of the magnetic path including the second iron core 3 through which the magnetic flux φB flows is orders of magnitude larger than the magnetic resistance of the magnetic path including the third iron core 5 serving as the common magnetic leg. Therefore, φB hardly flows in practice. That is, the magnetic flux generated in the first coil 2 is the third magnetic flux which is the common magnetic leg.
Most of the magnetic flux flows as φA into the closed circuit passing through the iron core portion 5 of the above, and the magnetic flux linked to the second coil 4 constituting the other inductance Ld flows only a minute amount that can be ignored in practical use.

On the contrary, the flow of the magnetic flux generated by the current of the second coil 4 is the same as that described so far, and most of the magnetic flux generated by the second coil 4 is the third iron core 5 having the common magnetic leg.
, And there is almost no magnetic flux linking with the first coil 2 beyond the third core portion 5.

As described above, even if the two inductances function at the same time, an integrated reactor that has little or no magnetic mutual influence or is practically negligible was realized. For reference, FIG. 6 shows how much the relative gap value of the core gap of the third iron core 5 is higher than that of the other first iron core 1 and the second iron core 3, and The tendency of the suppression effect is shown by taking the third harmonic of the harmonic current suppression value as an example. The waveform of the current flowing through each coil of the composite reactor of the present invention is almost the same as the waveform when using two independent reactors (FIG. 4).

When two conventional independent reactors are used, the electromagnetic design of the reactor is such that in an AC reactor, a magnetic flux proportional to the sum S ₁ + S ₂ of the integrated value of the current Ic flows. magnetic path cross section is required, whereas since the magnetic flux flows in proportion to the integral value S ₃ of the current Id is the magnetic path cross section corresponding to the required direct current for the reactor.

On the other hand, when two magnetic circuits which are magnetically almost independent from each other via the third iron core 5 which is a common magnetic leg are provided together as shown in FIG. 4, as in the embodiment of the present invention. When the currents Ic and Id flow through the first coil 2 and the second coil 4, respectively, ic and i flow through the third core 5 respectively.
The magnetic flux corresponding to d will merge. That is, i
A composite magnetic flux corresponding to the composite current I of c and id flows through the third core 5. Figure 4 is a phase opposite to each other with a clear manner Ic and Id S ₂ moiety and S ₃ parts partially offset result, the integrated value S ₄ of the composite current I using a conventional two independent reactors In this case, the current is greatly reduced as compared with the sum of currents S ₁ + S ₂ + S ₃ .

As can be seen from the above description, when the conventional two independent reactors are integrated and configured as in the present invention, the magnetic path disconnection of the third iron core 5 is originally required. Although the area should require a value corresponding to each integral value S ₁ + S ₂ + S ₃ , a magnetic path sectional area corresponding to the integral value S ₄ is sufficient. S ₁ + S ₂ of this S ₄
The ratio with respect to + S ₃ changes by adjusting the circuit constant and the reactor characteristic according to the target setting value of the harmonic current suppression, but is about one half in the present embodiment. Therefore, the cross section of the magnetic path of the third iron core 5 is about one half that of the conventional example.
And the amount of iron core can be greatly reduced, so that the reactor can be reduced in size, weight, and cost. As a reference, in FIG. 7, what is the relative value of the cross-sectional area of the third core 5 compared to the sum of the cross-sectional areas of the first core 1 and the second core 2, The tendency of harmonic current suppression effect is determined by the third harmonic current suppression value.
The harmonic is shown as an example.

It is to be noted that, as the core material of the third core portion 5, a magnetically permeable electromagnetic steel sheet such as a directional silicon steel sheet or the like is used or the thickness thereof is reduced, so that the harmonic current can be reduced. By maintaining the required permeability, the third core 5
Can be further reduced.

Further, since the magnetic steel sheet used for the iron cores 1, 3, 5 and the bridge iron core 8 can be made into a short fence type or trapezoidal type having a simple shape, an expensive punching die is not required, and it can be easily manufactured by shearing or the like. Also, the size of the magnetic steel sheet can be freely set as compared with the case of a conventional iron core shape such as EI type. This makes it possible to design the dimensions of the cores 1, 3, 5, and 8 for accommodating the coils to the required minimum dimensions for each model, thereby reducing the amount of material used for the cores 1, 3, 5, and 8. it can.

Further, as shown in FIG. 1, the two bridging core portions 8 are formed by cutting the corners that are not effective in view of the flow of magnetic flux, so that the material of the electromagnetic steel sheet 11 used for the bridging core portions 8 is used. In addition to reducing the volume, the weight of the reactor is also reduced. As shown in FIG. 8, the angle of the trapezoidal magnetic steel sheet 11 is from 60 ° to 80 ° from the practical characteristics.
And an example in which the electromagnetic steel sheet 11 is manufactured without material loss.

As shown in FIG. 9, when the width dimension A of the magnetic path cross section of the iron cores 1, 3, 5 is larger than the depth dimension B (lamination thickness), the depth dimension B is set to the core parts 1, 3, respectively. , 5
It is advantageous to reduce the number of laminations by setting the lamination thickness to be smaller, so that the cost of punching electromagnetic steel sheets used for the iron cores 1, 3, and 5 can be reduced. FIG. 10 shows a case where the dimensions A and B are opposite to the dimension A (lamination thickness) <the dimension B in FIG.

Further, by using an insulating sheet as the core gap spacers 6 and 7 necessary for securing the core gap, it is possible to save the number of members by combining the functions of securing the core gap size and insulating.

Further, the first iron core 1 and the second iron core 3
Are completely separated and insulated from the two bridging core portions 8, that is, the ground, by the core gap spacers 6 and 7 each also serving as an insulating sheet. Therefore, it is possible to realize a configuration in which the coils 2, 4 are not required to insulate the iron cores 1, 3 at all. As a result, the number of insulating materials can be reduced, and the number of assembly steps can be reduced by simplifying the insulating configuration. Further, as described above, there is no need for insulation between the coils 2, 4 and the iron cores 1, 3, so that there is no need to provide an insulation distance between the coils 2, 4 and the iron cores 1, 3, respectively. By minimizing the inner diameter of the wire, it is possible to greatly reduce the amount of electric wire used. In addition, it is also possible to wind the coil directly around the iron core,
Eliminating the need for a core jig and reducing the number of manufacturing steps by eliminating the need for separating the coil and the core jig after winding are possible.

Further, a U-shaped coil protection member 12 is attached to the outer periphery of the first core portion 1 or the second core portion 3 having a rectangular cross section, as shown in FIG. If the wire 4 is directly wound, it is useful as a structure for preventing the coil damage at the time of winding at the iron core corner portion 13.

Further, as shown in FIG.
It is also useful that the coil 2 or the coil 4 is wound directly on the iron core corner portion 13 by performing a rounding process on the iron core corner portion 13 without using any coil protection member.

FIGS. 13A and 13B and FIG. 14A
As shown in (B), a coil protection member 14 having R on the end face is installed at a side end of the iron core 1 or 3, respectively.
A structure in which the coil 2 or 4 is wound directly from above is also useful as preventing the coil wound due to the winding in the core corner 13.

Also, due to limitations on the characteristics of the reactor, the thickness dimensions of the gap spacers 6 and 7 for securing the core gap require considerable precision. Attempting to achieve this dimensional accuracy with a material that is not elastic in the thickness direction is very costly. On the other hand, in the present embodiment, an inexpensive material having elasticity in the thickness direction such as a glass nonwoven fabric, a polyester nonwoven fabric, and an aramid paper without calendering is used as the gap spacers 6 and 7, and two bridge iron core portions are used. When the core gap is pressed by pressing from above and below the core gap 8, the thickness of the core gap spacers 6, 7 having elasticity, that is, the core gap dimension changes according to the pressing force. At this time, a measuring instrument is connected to the coils 2 and 4 at the same time and pressed while measuring the inductance value. When the required inductance value is reached, the fixing metal 10 is easily fixed while maintaining the pressing force. A reactor having a required inductance value can be manufactured. By using an inexpensive material having elasticity as the gap spacer, the material cost can be reduced.

Further, as shown in FIG.
By setting the respective core dimensions and abutting positions so that the end faces of the bridges 5 always fit within the end faces of the bridge core 8, leakage magnetic flux can be absorbed by the bridge core 8, and Of the reactor characteristics due to misalignment between the iron cores can be suppressed.

FIGS. 16 to 23 show examples of combinations of iron core shapes useful for forming a sun-shaped magnetic path. These are also useful as a reactor structure having the same effects as the present embodiment.

(Embodiment 2) An example in which a part or the whole of the composite reactor of the present invention is molded with resin will be described as Embodiment 2 (not shown). That is, the cores 1, 3, 5, 8 and the coils 2, 4 are securely fixed by molding, and the molded part is easily provided with a terminal fixing part, a mounting part to other equipment, and the like, and is manufactured. A structure with a small number of steps and a high mass productivity can be obtained. In particular, by molding the entire composite reactor, the entire composite reactor is more completely fixed and isolated and protected from the outside, so it is extremely waterproof and suppresses noise and vibration generated from the composite reactor. Reactor structure can be obtained.

(Embodiment 3) FIG. 24 shows Embodiment 3 in which the composite reactor of the present invention is fixed by projection welding of an iron core.

At least one projection welding is performed at a portion where the two trapezoidal bridging core portions 8 abut against the third core portion 5 to thereby form the two bridging core portions 8 and the third bridging core portion 8. Is fixed to the iron core part 5. At this time, the iron cores 1 and 3 and the coils 2 and 4 are respectively
In a state where the two bridge iron cores 8 are installed at predetermined positions together with the bridge irons 7, the two bridge iron cores 8 are pressed from above and below and fixed. A projection 15 for projection welding is provided on the bridge core 8 or the third core 5 for projection welding. With this configuration, the reactor can be fixed without using the fixing fitting 10 of FIG. 1, so that the material cost can be reduced, and the outer dimensions of the reactor can be reduced by the amount of the fixing fitting 10, so that the reactor can be inserted into the equipment. It is effective in terms of storage.

The varnish impregnation is applied to the butted portions of the respective iron core portions, the coils 2, 4 and the like, so that the entire reactor is completely fixed.

(Embodiment 4) FIGS. 25A and 25B show Embodiment 4 relating to fixing of a reactor. FIGS. 25 (A) and 25 (B) show that a portion around the third iron core portion 5 at substantially the center of the reactor is clamped by a substantially U-shaped fixing bracket 16 and protrudes from two through holes 9A provided in the mounting plate 9. This shows a state where the tip of the fixing bracket 16 is welded and fixed around the through hole 9A of the mounting plate.

With such a structure, the iron cores 1, 3, 5,
Not only are the coils 8 and the coils 2 and 4 fixed, but also the fixing of the reactor to the mounting plate 9 is performed simultaneously.

Therefore, it is possible to obtain a reactor structure with a small number of assembly steps and high mass productivity. In addition, since the fixture 10 shown in FIG. 1 is not required, the external dimensions are reduced accordingly, which contributes to downsizing.

The fixing bracket 16 can be made of a non-magnetic material such as stainless steel if necessary.

Fifth Embodiment FIG. 26 shows a fifth embodiment relating to the shape of the magnetic path of the iron core. Note that portions common to the first embodiment are described using the same reference numerals as in FIG.

FIG. 26 shows two cores 1 and 3 combined with coils 2 and 4 and gap spacers 6 and 7, respectively.
A pair of pairs are housed in a window of a sun-shaped magnetic path to form a substantially U-shaped magnetic path. Here, the sun-shaped magnetic path has two C-shaped iron cores 17 and 18 and one I-shaped iron core 19. As in the case of the first embodiment, the I-shaped iron core 19 corresponds to the iron core portion 5 of the first embodiment by operating as two reactors in the DC power supply device shown in FIGS. The required core cross-sectional area is about half that of the core.

In this case, since the core gap dimensions at all butted portions of the iron core are fixed dimensions, a reactor structure having stable reactor characteristics without variation in core gap dimensions can be obtained. This structure is suitable for being fixed by welding at the end of the core butt, but other fixing means may be used. Although the size in the height direction increases, it is suitable for reducing the occupied area.

Embodiment 6 FIG. 27 shows Embodiment 6 relating to the shape of the magnetic path of the iron core. FIG. 27 shows cores 1 and 3, coils 2 and 4, and core gap spacers 6 and 7.
2 shows an arrangement in which two sets each of which are combined are arranged in a mouth-shaped magnetic path formed of at least one iron core to form a substantially O-shaped magnetic path. Here, an example in which the mouth-shaped magnetic path is composed of the L-shaped iron cores 20 and 21 is shown.

Also in the case of the sixth embodiment, the first embodiment
As in the case of the first embodiment, by operating as two reactors in the DC power supply device shown in FIGS. 2 and 3, the magnetic leg portions and some bridge portions of the L-shaped cores 20 and 21 are changed to the iron core of the first embodiment. 5, which similarly requires only a narrow magnetic path cross section.

Also in this case, as in the fifth embodiment, the core gap dimensions at all butted portions of the iron core are fixed dimensions, so that a reactor structure having stable reactor characteristics without variation in core gap dimensions can be obtained. . Also in this case, the butted portion of the L-shaped iron core 20 and the L-shaped iron core 21 is suitable for being fixed by welding, but other fixing means may be used.

(Embodiment 7) FIG. 28 shows Embodiment 7 relating to the shape of the magnetic path of the iron core.

Two sets each of which is composed of the iron cores 1 and 3 and the coils 2 and 4 and the gap spacers 6 and 7 and the iron core 5 interposed between the two sets are formed by the L-shaped iron cores 22 and 23. It is arranged in a mouth-shaped magnetic path. As described above, the magnetic path configuration is such that three magnetic legs are arranged in parallel in the square-shaped magnetic path. It is useful as a reactor configuration in which the mutual influence of two inductances is further reduced.

[0063]

As is apparent from the above description, the composite reactor according to the present invention comprises a first core having a first coil inserted therein and a second core having a second coil inserted therein. By adjusting the distribution of the core gap size at the abutting portion between the third core portion and the bridging core portion in which the magnetic fluxes of the coils cancel each other, the coupling between the two magnetic circuits is minimized, It is possible to realize an integrated composite reactor that can obtain almost independent inductance.
This provides an excellent effect of reducing the weight and cost.

Further, since the number of laminations can be reduced by selecting the lamination thickness of the laminated core and the dimensions of the core, the punching cost of the electromagnetic steel sheet can be reduced.

Further, by setting the contact position and the core size such that the end faces of the three magnetic legs do not protrude from the bridging core portion, the leakage magnetic flux generated due to the displacement of the butting of the iron core is absorbed, and the magnetic flux is stabilized. Reactor characteristics can be obtained.

The LC flowing through the two inductances
Due to the action of the resonance current, the magnetic fluxes converging to the third core, which is the common magnetic leg of the two magnetic circuits, are out of phase with each other and cancel each other. Thus, the required magnetic path cross-section can be minimized to 5%, and the size, weight and cost of the composite reactor can be reduced.

Further, the first coil and the second coil are inserted to determine the minute core gap between the third iron core and the bridging iron core, which are the common magnetic legs of the two magnetic circuits. By setting the core gap size of the first or second core portion to be 40% or less, the mutual influence of the two magnetic circuits can be suppressed to a level that causes no practical problem.

Further, by selecting the shape of the magnetic path formed by the respective iron core portions into the shape of the sun, the shape of the eye, the shape of the cross, etc., a useful structure in terms of assembling property and occupying space can be provided as required. You can also choose.

Further, according to the method for manufacturing a composite reactor of the present invention, the thickness of the gap spacer, which is the core gap size, is adjusted while measuring characteristics such as inductance value, and the pressing force when the required characteristics are obtained is obtained. Each core part is fixed by fixing means while maintaining the same, so that extremely high-precision thickness dimensions are required as gap spacers, and where extremely expensive materials are required, An inexpensive and unnecessary material can be used as the gap spacer, so that the cost of the material can be reduced, and the inductance value can be set freely by adjusting the pressing force.

Further, the power supply device of the present invention uses the composite reactor of the present invention for the harmonic suppression circuit, and uses the harmonic regulation value (I
EC equivalent level) can be completely cleared over all orders.

[Brief description of the drawings]

FIG. 1 is a schematic front view of a composite reactor according to Embodiment 1 of the present invention.

FIG. 2 is a diagram showing a first example of a power supply device using the composite reactor.
circuit diagram

FIG. 3 is a second circuit diagram of the power supply device.

FIG. 4 is a waveform diagram of a current flowing through the composite reactor.

FIG. 5 is an unsaturated closed magnetic circuit diagram showing a flow of a magnetic flux generated in a first coil of the composite reactor.

FIG. 6 is a characteristic diagram showing the relationship between each core gap and the third harmonic current of the hybrid reactor.

FIG. 7 is a graph showing the relationship between the cross-sectional area of each iron core and the third harmonic current of the composite reactor.

FIG. 8 is a cutaway drawing of a pressing process of an electromagnetic steel sheet used for an iron core of the composite reactor.

FIG. 9 is a perspective view showing an example of a stacking direction of each core portion of the composite reactor.

FIG. 10 is a perspective view showing another example of the stacking direction of each core portion of the composite reactor.

FIG. 11 is a perspective view showing a state where a coil protection member is arranged on an iron core of the composite reactor.

FIG. 12 is a perspective view showing an iron core of the composite reactor.

FIG. 13 (A) is a perspective view showing a state in which a coil is inserted into an iron core portion of the composite reactor.

FIG. 14 (A) is a perspective view showing another coil insertion state of the iron core portion of the composite reactor, and FIG. 14 (B) is an enlarged perspective view of the coil protection member of FIG.

FIG. 15 is a conceptual diagram showing an assembling arrangement state of an iron core portion of the composite reactor.

FIG. 16 is a conceptual diagram showing a second example of the core of the composite reactor.

FIG. 17 is a conceptual diagram showing a third example of an iron core of the composite reactor.

FIG. 18 is a conceptual diagram showing a fourth example of an iron core of the composite reactor.

FIG. 19 is a conceptual diagram showing a fifth example of the core of the composite reactor.

FIG. 20 is a conceptual diagram showing a sixth example of an iron core of the composite reactor.

FIG. 21 is a conceptual diagram showing a seventh example of the core of the composite reactor.

FIG. 22 is a conceptual diagram showing an eighth example of the core of the composite reactor.

FIG. 23 is a conceptual diagram showing a ninth example of the core of the composite reactor.

FIG. 24 is a conceptual diagram of the assembly of the composite reactor according to the third embodiment.

FIG. 25 (A) is a front view of a composite reactor according to Embodiment 4; FIG. 25 (B) is a perspective view of an essential part showing a mounting state of the fixing bracket of FIG.

FIG. 26 is a front view showing a tenth example of the core of the composite reactor of the fifth embodiment.

FIG. 27 is a front view showing an eleventh example of the core of the composite reactor of the sixth embodiment.

FIG. 28 is a front view showing a twelfth example of the core of the composite reactor of the seventh embodiment.

FIG. 29 is a front view of a conventional individual reactor.

[Explanation of symbols]

 1, 3, 5, 8 Iron core part 2, 4 Coil 6, 7 Gap spacer 9 Mounting plate 9A Through hole of mounting plate 10 Fixture 11 Magnetic steel plate 12 Coil protection member 13 Iron core part 14 Coil protection with R at corner Member 15 Projection welding protrusion 16 U-shaped fixing bracket 17, 18 C-shaped iron core 19 I-shaped iron core 20, 21, 22, 23 L-shaped iron core

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI H02M 1/14 H01F 27/24 H

Claims (22)

[Claims] 1. A first iron core part on which electromagnetic steel sheets are laminated and a first coil is inserted, a second iron core part on which electromagnetic steel sheets are laminated and a second coil is inserted, and an electromagnetic steel sheet are laminated. A bridging core portion for forming an unsaturated closed magnetic circuit via a predetermined core gap in each of the first and second core portions;
And a third core portion in which each magnetic flux generated by the second coil and the second coil flows in a direction offset from each other for at least a part of each cycle of the commercial power supply, and the third core portion is separated from the predetermined core gap. A composite reactor which is disposed between the bridging cores via a small core gap having a small gap, and the first, second, and third cores and the bridging core are integrally fixed by fixing means. 2. Between the first core and the bridge core, between the second core and the bridge core, and between the third core and the bridge core, respectively. The composite reactor according to claim 1, butted through a core gap. 3. The composite reactor according to claim 1, wherein the core gap is secured by interposing a gap spacer. 4. The composite reactor according to claim 3, wherein a member having elasticity at least in a thickness direction is used for the gap spacer. 5. The composite reactor according to claim 3, wherein an insulating sheet is used as the gap spacer. 6. The composite reactor according to claim 3, wherein a porous material or a fibrous material is used as the gap spacer. 7. The composite reactor according to claim 1, wherein at least a butt portion of each core portion is fixed by varnish impregnation as fixing means. 8. The composite reactor according to claim 1, wherein a part or the whole of the fixing means is resin cast or resin molded. 9. The composite reactor according to claim 1, wherein the bridging core is trapezoidal. 10. The composite reactor according to claim 1, wherein the first, second, and third core portions are laminated in a direction in which a smaller one of a width dimension and a depth dimension of a magnetic path cross section becomes a lamination thickness. 11. The composite reactor according to claim 1, wherein at least the end faces of the first, second, and third core portions are set to have the core portion dimensions and the abutting position so as to fit within both end surfaces of the bridging core portion. . 12. The composite reactor according to claim 1, wherein a coil is wound around a core corner of the first and second cores via a U-shaped coil protection member. 13. The combined reactor according to claim 1, wherein the core corners of the first and second cores are rounded and a coil is wound therearound. 14. The composite reactor according to claim 1, wherein the coil is wound by attaching a coil protection member having an R at the core corner to both ends of at least one pair of opposite sides of the first and second cores. . 15. The composite reactor according to claim 1, wherein the cross-sectional area of the third core is at least 5% of the sum of the cross-sectional areas of the first and second cores. 16. The minute core gap dimension between the third core part and the bridging core part is 40% or less of the predetermined core gap dimension between the first core part and the bridging core part; 40% of the specified core gap size between the iron core and the bridging iron
The composite reactor according to claim 1, wherein: 17. The composite reactor according to claim 1, wherein the butting portion of the third core portion and the two bridging core portions is fixed by performing projection welding. 18. A substantially U-shaped bracket for holding a substantially central portion of the reactor, and a through hole of a metal mounting plate attached to an outer end surface of one of the bridging iron cores. 2. The composite reactor according to claim 1, wherein two front ends are projected, and these are welded and fixed to a mounting plate around the through hole. 19. The unsaturated magnetic circuit formed by each of the iron core portions may be any one of a substantially sun-shaped, a roughly-shaped, and a substantially cross-shaped as viewed from the top and bottom of the two coils. The composite reactor according to claim 1, wherein the composite reactor is integrally fixed so as to have the following configuration. 20. A first iron core formed by stacking electromagnetic steel sheets having a first coil inserted therein, a second iron core formed by stacking electromagnetic steel sheets having a second coil inserted therein, First and second
Each having a bridging core portion formed by laminating electromagnetic steel sheets for forming unsaturated magnetic paths through predetermined core gaps on the iron core portion of each of the first and second coils. A third core portion flowing in a direction offset with respect to each other for at least a part of a period of each cycle of the commercial power supply, wherein the third core portion is provided between the bridging core portions via a small core gap having a smaller gap than the predetermined core gap. By arranging the iron core of No. 3, a substantially sun-shaped, eye-shaped or cross-shaped magnetic path is formed, and the bridge iron is pressed while measuring the reactor characteristics such as inductance value. A method for manufacturing a composite reactor in which a thickness of a gap spacer, which is a core gap dimension, is adjusted, and a bridge core is fixed by fixing means while maintaining a pressing force when required characteristics are obtained. 21. A power supply device for forming a DC power supply by rectifying a single-phase AC using the composite reactor according to claim 1, wherein the composite reactor is provided between a diode bridge for full-wave rectification and a smoothing capacitor. A power supply device, wherein a series circuit of a first coil and a diode is connected in parallel with a series circuit of a second coil and a capacitor of the composite reactor. 22. A power supply apparatus for forming a DC power supply by rectifying a single-phase alternating current using the composite reactor according to claim 1, wherein the first reactor of the composite reactor is provided at a stage subsequent to a diode bridge for full-wave rectification. And a series circuit including a coil and a diode smoothing capacitor, and a series circuit including a second coil and a capacitor of the composite reactor.