CN101816051A - Electromagnetic device - Google Patents

Abstract

The reactor (1) includes a central core (2), a coil (3) arranged around the central core (2), a U-shaped core (4) having an open side and covering all outer peripheral surfaces except for the portion of the coil, a top core (5) covering the upper ends of the central core (2) and the coil (3), and a bottom core (6) covering the lower ends of the central core (2) and the coil (3). In the reactor (1), the portion (3a) of the outer peripheral surface of the coil (3) located on the open side of the U-shaped core (4), the open end portion (4a) of the U-shaped core (4), one side portion (5a) of the top core (5), and one side portion (6a) of the bottom core (6) are adjacent to the cooling component (9).

Description

electromagnetic device

technical field

The invention relates to electromagnetic devices such as transformers, choke coils or reactors with cores and coils.

Background technique

Examples of known electromagnetic devices such as transformers, choke coils or reactors with core and coils are reactors used in drive circuits of electric vehicles. The reactor transforms current using inductive reactance, and is formed with an iron core and a coil. The reactor is used in conjunction with a switching circuit. By repeatedly switching the reactor on and off, the reactor generates energy stored in the coil when on and energy as back electromotive force (ie, back EMF) when off, allowing high voltage to be obtained.

In order to suppress heat generation in a reactor supplied with a large current value, it is necessary to cool the reactor. One example of a technique for cooling a reactor is described in Japanese Patent Application Publication No. 2005-286020 (JP-A-2005-286020), which describes a cooling structure in which a shell portion of a reactor is integrally formed with a radiator . That is, in the structure for mounting the reactor to the case housing the driving control apparatus of the electric motor for driving the vehicle, openings communicating between the coolant passages are formed in the radiator of the case. A seal surrounding the opening is provided between the heat sink and the reactor. In a state where the opening is closed by the bottom surface of the reactor and the bottom of the reactor is in contact with the coolant, the casing of the reactor is mounted to the radiator outside the opening. The reactor is cooled by bringing the bottom of the reactor into contact with the coolant in this way.

However, according to the cooling structure described in JP-A-2005-286020, the core and the coil of the reactor are mounted to the radiator via the case, so that cooling is performed indirectly, and thus may be insufficient. Also, when the reactor is used with a boost circuit in a hybrid system, the reactor must have a flat DC superposition characteristic. In order to meet this requirement, the temperature of the coils of the reactor must be adjusted such that the permissible temperature is not exceeded. Typically, the temperature of the coil is monitored and the coil temperature is prevented from increasing by controlling the coil current. However, monitoring the temperature of the coil requires a temperature relay and a control circuit for temperature monitoring, resulting in a more complicated structure.

Also, with the structure described in JP-A-2005-286020, the area where the coil is cooled is relatively small or absent.

On the other hand, Japanese Patent Application Publication No. 2005-286020 (JP-A-2005-286020) proposes a coil component in which a core and a coil are in direct contact with a cooling device. However, according to the structure described in JP-A-2005-286020, a column is required to connect the coil to the cooling device, complicating the structure of the cooling device.

Contents of the invention

The present invention provides an electromagnetic device capable of improving cooling capacity with a simple structure.

One aspect of the present invention relates to an electromagnetic device, comprising: a cylindrical central core; a coil disposed around the central core; a U-shaped core having an open side and covering all outer peripheral surfaces except a portion of the coil; a top core having covering the center core and one end of the coil in the vertical direction of the center core; and a bottom core covering the center core and the coil in the vertical direction of the center core the other end of each. A portion of the outer peripheral surface of the coil on the opening side of the U-shaped core, an open end portion of the U-shaped core, a side portion of the top core, and a side portion of the bottom core are adjacent to the cooling unit.

According to this aspect, a part of the outer peripheral surface of the coil located on the opening side of the U-shaped core, an opening end portion of the U-shaped core, a side portion of the top core, and the bottom core Parts of one side of both sides are adjacent to the cooling part, so that not only the U-shaped core, the top core and the bottom core are directly cooled by the part close to the cooling part, but also the coil is directly cooled by the part close to the cooling part. Also, the structure of the cooling part can be simplified. Also, the top core and the bottom core are adjacent to the cooling member, so that the coil and the U-shaped core can also be directly cooled by the cooling member. That is, the electromagnetic device can be cooled better with a simple structure.

In the above structure, the coil may be disposed around the center core formed in a polygonal column shape, and the portion of the outer peripheral surface of the coil is the largest surface of the center core formed in a polygonal column shape.

In the above structure, the center core may be formed in a rectangular columnar shape, and a surface having a rectangular long side is the part of the outer peripheral surface of the coil.

In the above structure, the part of the outer peripheral surface of the coil located on the opening side of the U-shaped core, the opening end part of the U-shaped core, the one of the top cores Both the side portion and the side portion of the bottom core abut one face of the cooling member.

In the above structure, the one surface of the cooling member may be a flat surface.

According to this structure, the electromagnetic device can be cooled by one face of the cooling member, thereby allowing the cooling member to be formed in a simple plate-like manner.

In the above aspect, the slit may be provided at the center of the one side portion of the top core adjoining the cooling member, and on the center line of the opening of the U-shaped core. And, a coil terminal may be provided at a part of the coil, and the coil terminal may extend upward in a longitudinal direction of the center core through the cutout.

According to this structure, the center of the one side portion adjacent to the top core of the cooling member and located on the center line of the opening of the U-shaped core is a portion where magnetic flux with the coil becomes sparse. Corresponding. Therefore, a slit is formed in the top core at a position corresponding to a portion where the magnetic flux of the coil becomes sparse, and the coil terminal protrudes upward from the top core through the slit, so that neither the slit nor the coil terminal greatly affects magnetic flux. Pass. That is, the coil terminal can be easily provided without affecting the performance of the electromagnetic device or increasing the size of the electromagnetic device.

In the above structure, a concave portion may be provided at a position adjacent to the cutout of the top core and on a center line of the opening of the U-shaped core; and a fixing member may be provided in the concave portion .

According to this structure, the portion of the top core adjoining the cutout corresponds to the portion where the magnetic flux of the coil becomes sparse (as the cutout portion). Therefore, a concave portion is formed in the top core at a position corresponding to a portion where the magnetic flux of the coil becomes sparse, so that the concave portion does not affect the magnetic flux too much. And, the fixing part is placed in the concave part so as not to protrude. That is, the electromagnetic device can be effectively fixed using the fixing member without affecting the performance of the electromagnetic device or increasing the size of the electromagnetic device.

In the above structure, a non-magnetic plate may be in-molded on the center core, and a spacer plate for maintaining a spaced width may be provided between the top core and one end in the longitudinal direction of the center core, and with A spacer plate for maintaining a spaced width may be provided between the bottom core and the other end in the longitudinal direction of the center core. Also, one of the spacer plates disposed corresponding to the one end in the longitudinal direction of the center core may be integrally formed with the center core. In addition, another of the spacer plates disposed corresponding to the other end in the longitudinal direction of the center core may be formed separately from the center core to allow the coil to be inserted into the center core.

According to this structure, the spacer plates are provided for maintaining the distances between the upper end of the center core and the top core and between the lower end of the center core and the bottom core. This allows a constant insulation distance to be maintained between the top core and the center core, U-shaped core, coil and between the bottom core and the center core, U-shaped core, coil. In addition, one spacer plate provided corresponding to one end in the longitudinal direction of the center core is integrally formed with the center core, so the number of parts is reduced compared to when the spacer plate and the center core are separately provided. That is, the interval widths between the center core and the top core and between the center core and the bottom core can be maintained, and the realization structure thereof can be simplified to improve assemblability.

In the above structure, fitting portions that fit each other in a concave-convex relationship may be provided on each of the spacer plates and the top core and the bottom core. And, the top core is positioned relative to the partition plate by fitting of the fitting portion, and the bottom core is positioned relative to the partition plate by fitting of the fitting portion.

According to this structure, the top core and the bottom core are positioned on the spacer plate by the fitting of the fitting portion, so there is no need to provide a separate component for positioning. Also, the fitting portions are fitted in a concavo-convex relationship, so that they can be easily formed. That is, the top core and the bottom core can be positioned on the spacer plate with a relatively simple structure, and vibration between parts can be prevented.

Description of drawings

The foregoing and further objects, features and advantages of the present invention will become apparent from the following description of preferred embodiments with reference to the accompanying drawings, wherein like numerals are used to represent like elements, wherein:

Figure 1 is a perspective view of a reactor according to a first exemplary embodiment of the present invention;

Figure 2 is an exploded perspective view of the reactor;

Figure 3 is a sectional view taken along plane III-III in Figure 1 showing the reactor;

Fig. 4 is an enlarged cross-sectional view of a part inside the rectangular dot-dash line shown in Fig. 3 when viewed from the front;

Figure 5 is a longitudinal sectional view showing the reactor in use;

Figure 6 is a plan view showing the reactor in use with the top core removed;

7 is a view showing the magnetic flux distribution of the coil when viewed from the front;

Fig. 8 is a view showing the magnetic flux distribution of the coil when viewed from the side;

Fig. 9 is a view showing the magnetic flux distribution of the coil after removing the top core;

FIG. 10 is a plan view showing a magnetic flux distribution of a coil;

Figure 11 is a circuit diagram of a hybrid power system for which the reactor is used;

12 is a graph showing DC superposition characteristics (CAE calculated values) of a reactor in a hybrid system;

Figure 13 is a perspective view of a reactor according to a second exemplary embodiment of the present invention;

Figure 14 is an exploded perspective view of the reactor;

Figure 15 is a partially exploded perspective view of the reactor with the coil removed;

16 is a view showing the relationship between the concave portion of the top core and the convex portion of the upper gap plate;

17 is a view showing the relationship between the concave portion of the bottom core and the convex portion of the lower gap plate; and

Fig. 18 is a view showing the relationship between the concave portion of the center core and the convex portion of the lower gap plate.

Detailed ways

Next, a first exemplary embodiment in which the electromagnetic device of the present invention is implemented as a reactor will be described in detail with reference to the accompanying drawings.

FIG. 1 is a perspective view of a reactor 1 . In this example embodiment, the right side of the reactor in FIG. 1 is the front side of reactor 1 . FIG. 2 is an exploded perspective view of the reactor 1 . FIG. 3 is a sectional view (ie, a longitudinal sectional view) of the reactor 1 taken along plane III-III in FIG. 1 . FIG. 4 is an enlarged cross-sectional view of a portion within a rectangular region Q1 outlined by a dashed-dotted line shown in FIG. 3 when viewed from the front. FIG. 5 is a longitudinal sectional view showing the reactor in use, and FIG. 6 is a plan view showing the reactor 1 in use with the top core 5 removed.

As shown in FIGS. 1 to 3 , the reactor in this exemplary embodiment has a columnar central core 2, a coil 3 arranged around the central core 2, has an open side and covers all peripheral sides of the coil 3 except one portion. A U-shaped core 4, a top core 5 covering the upper ends of the central core 2 and the coil 3, and a bottom core 6 covering the lower ends of the central core 2 and the coil 3. Nonmagnetic plate 7 is arranged between top core 5 and center core 2 , upper ends of coil 3 , and nonmagnetic plate 8 is arranged between bottom core 6 and center core 2 , lower ends of coil 3 . Here, the portion of the outer peripheral surface of the coil 3 (ie, the front surface 3 a ) located on the opening side of the U-shaped core 4 , the open end portion of the U-shaped core 4 (ie, the open end surface 4 a ), one side portion of the top core 5 (i.e., the front side surface 5a), and one side of the bottom core 6 (i.e., the front side surface 6a) are flush with each other, and as shown in FIGS. 9a.

In this example embodiment, the reactor 1 may be used, for example, in a hybrid system of a hybrid vehicle. The above-mentioned cooling unit 9 is provided separately from the reactor 1 and is used for cooling the reactor 1 and electrical equipment around the reactor 1 . A coolant passage 9 b through which coolant flows is formed inside the cooling member 9 .

The center core 2 is formed of a rectangular columnar powder magnet core, ferrite, or the like. As shown in FIG. 6 , the center core 2 is rectangular in plan view with long sides arranged parallel to the front and rear sides of the reactor 1 . In order to obtain a flat stacking characteristic, a plurality of non-magnetic plates 10 are in-molded at intervals of equal distances in the middle portion of the central core 2 . These non-magnetic plates 10 create magnetic gaps.

The coil 3 is arranged around the center core 2 so as to surround it. As shown in FIG. 6 , the shape of the coil 3 matches that of the center core 2 , and is substantially rectangular when viewed from above, with long sides arranged parallel to the front and rear sides of the reactor 1 . The coil 3 is an edgewise coil in which a material strip of a predetermined width (for example, a rectangular or flat wound coil) is vertically and repeatedly wound. The height of the coil 3 is slightly smaller than that of the central core 2 .

One end portion 3 b of the strip of material forming the coil 3 is bent so as to stand vertically at the center on the upper surface of the front portion of the coil 3 . The other end 3c of the strip of material forming the coil 3 is bent so that it extends from the lower surface of the front of the coil 3 along the sides and then up the upper surface to a center on the upper surface where it is bent upwards, Thus standing vertically parallel to the end portion 3b. One end portion 3 b and the other end portion 3 c constitute a coil terminal 11 . In this way, the coil terminal 11 of the reactor 1 extends upward from the center of the upper end at the front portion of the coil adjacent to the cooling member 9 .

As shown in FIG. 6, the U-shaped core 4 is formed in a U-shape when viewed from above, and is made of powder magnet core or ferrite or the like. The U-shaped core 4 covers three adjacent sides (left side, right side and rear side) of the coil 3, leaving the front surface 3a of the coil 3 open. The height of the U-shaped iron core 4 is equal to the height of the central iron core 2 . The top core 5 and the bottom core 6 have a predetermined thickness, have the same shape, and are vertically symmetrically arranged to each other. The outer shape of the top core 5 and the bottom core 6 is substantially the same as that of the U-shaped core 4 .

The non-magnetic plate 7 is interposed between the top core 5 and the upper ends of the center core 2, U-shaped core 4, thereby separating the top core 5 from the center core 2, U-shaped core 4, so that flat stacking characteristics can be obtained. Similarly, a non-magnetic plate 8 is interposed between the bottom core 6 and the lower ends of the center core 2, U-shaped core 4, thereby separating the bottom core 6 from the center core 2, U-shaped core 4, so that flat stacking characteristics can be obtained . The outer shapes of the non-magnetic plates 7 and 8 substantially coincide with those of the top core 5 and the bottom core 6, respectively.

Here, as shown in FIGS. 5 and 6 , the center axis L1 of the center core 2 is shifted forward from the center axis L2 of the reactor 1 . Correspondingly, the coil 3 is offset from the center of the reactor 1 towards the side 9 a of the cooling part 9 .

As shown in FIGS. 1 to 3 , a slit 5 b is formed at the center of the front side of the top core 5 along the center line of the opening in the U-shaped core 4 , and a slit 7 b is also formed along the center line of the opening in the U-shaped core 4 . Formed in the center of the front side of the upper non-magnetic plate 7 . Coil terminals 11 protrude upward from top core 5 through cutouts 7b and 5b. Also, a concave portion 5 c is formed along the center line of the opening in the U-shaped core 4 at a position adjacent to the cutout 5 b in the top core 5 . A leaf spring 12, which can correspond to a fixing member of the present invention, is provided in this concave portion 5c. The leaf spring 12 is formed to be bent in a substantially U-shape and is integrally accommodated in the concave portion 5c. The bottom core 6 and the lower nonmagnetic plate 8 are formed similarly to the top core 5 and the upper nonmagnetic plate 7 . The reference numerals of the bottom core 6 and the lower non-magnetic plate 8 corresponding to the top core 5 and the upper non-magnetic plate 7 denote the same structure. However, no leaf spring 12 is provided in the concave portion 6 c of the bottom core 6 .

As shown in FIG. 5 , the reactor 1 is arranged adjacent to the cooling member 9 on the inverter case 21 and held in position by being pressed from above by the cover plate 22 . In this exemplary embodiment, the reactor 1 is sandwiched from above and below by fastening the cover plate 22 to the inverter case 21 with bolts or the like. Thus, the reactor is fixed to the inverter case 21 while the leaf spring 12 generates pressure.

In this exemplary embodiment, the concave portions 5c and 6c and the cutouts 5b and 6b are formed toward the front of the top core 5 and the bottom core 6 as described above, but this does not affect the performance of the reactor 1 because the magnetic flux of the coil 3 The relationship between the density distribution. FIG. 7 is a view showing the magnetic flux distribution of the coil 3 as viewed from the front of the reactor 1 . FIG. 8 is a view showing the magnetic flux distribution of the coil 3 when viewed from the side of the reactor 1 . FIG. 9 is a view showing the magnetic flux distribution of the coil 3 with the top core 5 of the reactor 1 removed. FIG. 10 is a view showing the magnetic flux distribution of the coil 3 when viewed from above the reactor 1 . As shown by the bold arrows in Figures 7 to 9, in the reactor 1, the magnetic flux of the coil 3 flows sequentially from the central core 2 to the top core 5, the U-shaped core 4 and the bottom core 6, and then returns to Center core 2. In this case, the U-shaped core 4 is open on the side where the cooling part 9 is located, ie on the front side, so that the magnetic flux distribution avoids the front side of the U-shaped core 4 . Also, the nature of the magnetic flux is to take the shortest magnetic path, so the magnetic flux is distributed along the outer peripheral portion of the center core 2 , producing portions where the magnetic flux is concentrated at the top core 5 and the bottom core 6 . Accordingly, as shown in FIG. 10 , a sparse magnetic flux region Mf having very little magnetic flux is generated on the center line C1 at the opening of the reactor 1 toward the front side of the top core 5 . A sparse magnetic flux region Mf is also generated in the periphery of the top core 5 . The same applies to the bottom core 6 . Therefore, in this exemplary embodiment, the cutouts 5b and 6b and the concave portions 5c and 6c are respectively formed in the top core 5 and the bottom core 6 at positions corresponding to the sparse magnetic flux region Mf of the reactor, so that these cutouts 5b and 6b and the concave portions 5c and 6c have very little influence on the magnetic flux.

According to the reactor 1 of this exemplary embodiment described above, the front surface 3a of the coil located on the front side of the U-shaped core 4, the open end surface 4a of the U-shaped core 4, the front side surface 5a of the top core 5, and the bottom core 6 The front side surfaces 6 a both adjoin one side face 9 a of the cooling part 9 . Therefore, not only the U-shaped core 4 , the top core 5 , and the bottom core 6 are directly cooled from a portion near the cooling member 9 but also the coil 3 is directly cooled from a portion near the cooling member 9 . Therefore, the ability to cool the reactor can be improved. Specifically, cooling capacity can be improved by directly cooling the coil 3 . Also, the coil 3, the U-shaped core 4, the top core 5, and the bottom core 6 are all cooled by one side surface 9a of the cooling member 9, which can be formed in a simple placoid manner.

Also, according to the reactor in this exemplary embodiment, one of the long sides of the coil 3 having a rectangular shape viewed from above adjoins the cooling member 9 . Therefore, the area of the coil 3 facing the cooling member 9 can be increased compared to one of the short sides of the coil 3 adjoining the cooling member 9 , thereby allowing the coil 3 to be cooled more easily.

Here, the related art JP-A-2005-286020 requires an additional structure including a temperature relay, a control circuit and the like for monitoring the temperature to prevent the coil temperature of the reactor from rising. According to this example embodiment, however, such an additional structure may be omitted. Furthermore, the reactor 1 can be effectively cooled only by the structure of the reactor 1 itself. Accordingly, the ability to cool the reactor 1 can be improved with a simple structure.

Related art JP-A-2002-252122 requires a column to connect the coil to the cooling device, complicating the structure of the cooling device. According to this exemplary embodiment, not only the coil 3 and the U-shaped core 4 but also the top core 5 and the bottom core 6 are cooled by the cooling member 9 formed in a simple plate shape.

According to the reactor 1 of this exemplary embodiment, the non-magnetic plate 7 is disposed between the top core 5 and the center core 2, the upper ends of the coil 3, and the non-magnetic plate 8 is disposed between the bottom core 6 and the center core 2, the lower ends of the coil 3 between. Accordingly, gaps of fixed width can be ensured between the top core 5 and the center core 2 and the upper ends of the coil 3 and between the bottom core 6 and the center core 2 and the lower ends of the coil 3 . Therefore, constant insulation distances can be secured between the top core 5 and the center core 2, U-shaped core 4, and coil 3, and between the bottom core 6 and the center core 2, U-shaped core 4, and coil 3.

According to the reactor 1 of this exemplary embodiment, the center line of the opening of the U-shaped core 4 , the center of the front side portion of the top core 5 adjoining the cooling member 9 corresponds to the portion where the magnetic flux of the coil 3 becomes rarefied. Therefore, the cutout 5b is formed in the top core 5 at a position corresponding to the portion where the magnetic flux of the coil 3 becomes thinner, and the coil terminal 11 protrudes upward from the top core 5 through the cutout 5b, so that both the cutout 5b and the coil terminal 11 are sensitive to the magnetic flux. Has little effect. Thus, the coil terminal 11 can be easily provided without affecting the performance of the reactor 1 or increasing the size of the reactor 1 .

According to the reactor 1 of this exemplary embodiment, the portion of the top core 5 adjoining the cutout 5b corresponds to the portion where the magnetic flux of the coil 3 becomes sparse, just like the portion of the cutout 5b. Therefore, the concave portion 5c is formed in the top core 5 corresponding to the position where the magnetic flux becomes sparse, so that the influence of the concave portion 5c on the magnetic flux will be small. Also, the fixed plate spring 12 is seated in the concave portion 5c so as not to protrude. Furthermore, the reactor 1 is fixed to the inverter case 21 by pressure from the leaf spring 12 . Therefore, the reactor 1 can be efficiently fixed to the inverter case 21 using the leaf spring 12 without affecting the performance of the reactor 1 or increasing the size of the reactor 1 .

FIG. 11 is a circuit diagram of a hybrid system to which the reactor 1 of the present exemplary embodiment is used. The system includes a pair of generators 31 and 32, a pair of inverters 33 and 34 that control power to the generators 31 and 32, a DC/DC converter 35 that supplies current to the inverters 33 and 34, and includes A battery 36 powers the circuit 37 . The inverters 33 and 34 are formed of a plurality of transistors. The reactor 1 of this example embodiment is connected between a pair of transistors 38 , 38 and a capacitor 40 in a DC/DC converter 35 . In this hybrid system, the reactor 1 is used to step up (ie, increase) the voltage of the power supply circuit 37 and supply it to the inverters 33 and 34 .

FIG. 12 is a graph showing the DC superposition characteristic (CAE calculated value) of the reactor in the hybrid system described above. It is evident from the curve that the cooling capacity of reactor 1 is very good, as described above, so that a very good flat stacking characteristic can be obtained.

Next, a second exemplary embodiment in which the electromagnetic device of the present invention is implemented as a reactor will be described in detail with reference to the accompanying drawings. Meanwhile, in the following description, constituent elements of the second exemplary embodiment that are equivalent to those of the first exemplary embodiment will be denoted by the same reference numerals, and descriptions of these elements will be omitted. The following description will mainly focus on the points of difference of the second exemplary embodiment from the first exemplary embodiment described above.

FIG. 13 is a perspective view of a reactor 41 according to a second exemplary embodiment. In this example embodiment, the close side of the reactor 41 in FIG. 13 is the front side of the reactor 41 . FIG. 14 is an exploded perspective view of the reactor 41, and FIG. 15 is a partially exploded perspective view of the reactor 41 with the coil 3 removed. This exemplary embodiment differs from the first exemplary embodiment in that a structure for positioning the constituent elements 2, 4 to 6, etc. relative to each other is provided.

That is, as shown in FIGS. 13 to 15 , the reactor 41 of this exemplary embodiment has a plurality of non-magnetic plates 10 molded on the center core 2 and has a function for maintaining the top core 5 and the upper end of the center core 2. The gap plate 42 of the gap width and the gap plate 43 for maintaining the gap width between the bottom core 6 and the lower end of the center core 2 . An upper gap plate disposed corresponding to the upper end of the center core 2 is integrally formed with the center core 2 . The lower gap plate 43 disposed corresponding to the lower end may be separated from the center core 2 so that the coil 3 can be inserted into the center core 2 . That is, in the first exemplary embodiment, the nonmagnetic plate 7 formed of separate components is provided between the upper end of the center core 2 and the top core 5, and the nonmagnetic plate 8 also formed of separate components is provided at the center core 2 between the lower end and the bottom core 6. However, in this exemplary embodiment, the non-magnetic plates 7 and 8 are omitted. Instead, there is an upper gap plate 42 provided integrally with the center core 2 and a lower gap plate 43 detachable from the center core 2 . Each of the upper gap plate 42 and the lower gap plate 43 can be formed by adding a filling material to a resin such as PPS (polyphenylene sulfide).

Furthermore, the reactor 41 of this exemplary embodiment is different from the above-described first exemplary embodiment in the shapes of the U-shaped core 4 , the top core 5 , and the bottom core 6 when viewed from above. That is, in this exemplary embodiment, the corner portions of the U-shaped core 4 form right angles. The shapes of the top core 5 and the bottom core 6 are substantially rectangular when viewed from above, and match the shape of the U-shaped core 4 . Also, the shapes of the upper gap plate 42 and the lower gap plate 43 are substantially rectangular, and match the shapes of the top core 5 and the bottom core 6 .

A plurality of fitting portions 44 that cooperate with the gap plates 42, 43 and the top core 5, bottom core 6 in a concave-convex relationship are provided on the reactor 41 of this exemplary embodiment. These mating portions 44 cooperate to position the top core 5 with respect to the gap plate 42 and the bottom core 6 with respect to the gap plate 43 . That is, a convex portion 42a protruding upward is integrally formed at each of four corners of the upper surface of the upper gap plate 42, while a plurality of concave portions 5d corresponding to the convex portion 42a are formed under the top core 5. formed at each of the four corners of the surface. The convex portion 42 a and the concave portion 5 d jointly form a fitting portion 44 .

FIG. 16 is a view showing the relationship between the convex portion 42a and the concave portion 5d. As evident from FIG. 16, the depth D1 of the concave portion 5d is slightly greater than the height of the convex portion 42a, so that the convex portion 42a fits completely within the concave portion 5d. Also, a convex portion 43 a protruding downward is integrally formed at each of four corners of the lower surface of the lower gap plate 43 . A concave portion 6 d corresponding to the convex portion 43 a is formed at each of the four corners of the upper surface of the bottom core 6 . FIG. 17 is a view showing the relationship between the convex portion 43a and the concave portion 6d. As evident from FIG. 17, the depth D2 of the concave portion 6d is slightly greater than the height of the convex portion 43a, so that the convex portion 43a fits completely within the concave portion 6d.

Also, in the reactor 41 of this exemplary embodiment, three protruding bars 42 b protruding downward are integrally formed at positions of the left, right and rear sides of the lower surface of the upper gap plate 42 . Similarly, three protruding bars 43 b protruding upward are integrally formed at positions on the left, right and rear sides of the upper surface of the lower gap plate 43 . These protruding strips 42 b and 43 b fit into the gap between the coil 3 and the U-shaped core 4 , thereby maintaining a constant insulating distance between the coil 3 and the U-shaped core 4 . These protruding bars 42b and 43b also determine the relative positions of the top core 5 and the bottom core 6 with respect to the central core 2 and the U-shaped core.

Further, as shown in FIGS. 14 and 15 , in the reactor 41 of this exemplary embodiment, four convex portions 43 c protruding upward are integrally formed on the central portion of the upper surface of the lower gap plate 43 . Also, concave portions 2a that fit into these convex portions 43c are formed on the four sides of the central portion of the lower end of the center core 2 corresponding to the convex portions 43c. FIG. 18 is a view showing the relationship between the convex portion 43c and the concave portion 2a. Fig. 18 clearly shows that the depth D3 of the concave portion 2a is slightly greater than the height H3 of the convex portion 43c, so that the convex portion 43c fits completely in the concave portion 2a.

According to the reactor 41 of the second exemplary embodiment described above, basically the same effects as those of the reactor of the first exemplary embodiment can be obtained. Furthermore, according to the reactor 41 of the second exemplary embodiment, the gap plates 42 , 43 are configured for maintaining gap widths between the upper end of the center core 2 and the top core 5 and between the lower end of the center core 2 and the bottom core 6 . This can maintain a constant insulation distance between the top core 5 and the center core 2, U-shaped core 4, coil 3 and between the bottom core 6 and the center core 2, U-shaped core 4, coil 3. Furthermore, the upper gap plate 42 provided corresponding to the upper end of the center core 2 is integrally formed with the center core 2 , thereby reducing the number of parts compared to when the gap plate 42 is provided independently of the center core 2 . Therefore, the gap width can be maintained between the center core 2 and the top core 5 and between the center core 2 and the bottom core 6, and the realization structure thereof can be simplified, improving assemblability.

According to the reactor 41 of this exemplary embodiment, the top core 5 and the bottom core 6 are respectively positioned on the gap plates 42 and 43 by fitting of the fitting portion 44, so that there is no need to provide a separate component for positioning. Also, the fitting portion 44 has the concave portions 5d, 6d and the convex portions 42a, 43b fitted in a concavo-convex relationship, and thus can be easily formed on the gap plates 42, 43 and the top core 5 and bottom core 6. Therefore, the top core 5 and the bottom core 6 can be respectively positioned on the gap plates 42 and 43 with a relatively simple structure, and vibration between the components 5 , 6 , 42 and 43 can be prevented.

According to the reactor 41 of this exemplary embodiment, the protruding strips 42b and 43b respectively provided on the gap plates 42 and 43 can maintain a fixed insulation distance between the coil 3 and the U-shaped core 4, so that the central core 2, the U-shaped The core 4, the top core 5 and the bottom core 6 are positioned relative to each other. Therefore, the top core 5 and the bottom core 6 can be positioned relative to the gap plates 42 and 43 , respectively, with a relatively simple structure, and vibration between the components 5 , 6 , 42 and 43 can be prevented.

Also, according to the reactor 41 of this exemplary embodiment, the center core 2 is positioned on the lower gap plate 43 by the convex portion 43 c provided on the lower gap plate 43 and the concave portion 2 a provided on the center core 2 . Therefore, the center core 2 can be positioned relative to the lower gap plate 43 with a relatively simple structure, and vibration between the components 2 and 43 can be prevented.

Meanwhile, the present invention is not limited to the above-described exemplary embodiments. That is, as described below, part of the structure may be appropriately modified as long as it does not depart from the scope of the present invention.

(1) In the first exemplary embodiment described above, a plurality of magnetic gaps are formed by arranging a plurality of non-magnetic plates 10 at equal intervals in the middle portion of the center core 2 to obtain a flat stacking characteristic. In contrast, by forming the entire center core from a lower permeability material, the magnetic gap can be omitted.

(2) In the above-described exemplary embodiments, the electromagnetic device of the present invention is implemented as the reactors 1 and 41 . Alternatively, however, the electromagnetic device can also be embodied as a choke coil or a transformer.

While the invention has been described with reference to example embodiments, it is to be understood that the invention is not limited to the described embodiments and constructions. On the contrary, the invention is intended to cover various modification and equivalent arrangements. In addition, while the various elements of the disclosed invention are shown in various example combinations and configurations, other combinations and configurations, including more, less or only a single element, are also within the scope of the following claims.

Claims (9)

1. calutron comprises:

The center iron core of column; The coil that is provided with unshakable in one's determination around described center; The U-iron heart, it has open side and covers all outer peripheral faces except the part of described coil; The top iron core, it covers the end separately on the vertical direction of described center iron core of described center iron core and described coil; And the bottom iron core, the other end separately on the vertical direction of described center iron core that it covers described center iron core and described coil is characterised in that:

The one side part of the part of the outer peripheral face of the described open side that is positioned at the described U-iron heart of described coil, the open end portion of the described U-iron heart, described top iron core and the side part of described bottom iron core are in abutting connection with cooling-part.

2. calutron according to claim 1, wherein, described coil is provided with around the described center that forms the polygon column is unshakable in one's determination, and the described part of the outer peripheral face of described coil is the maximum surface that forms the described center iron core of polygon column.

3. calutron according to claim 2, wherein, described center iron core forms the rectangle column, and the surface with long limit of rectangle is the described part of the outer peripheral face of described coil.

4. according to each described calutron in the claim 1 to 3, wherein, be positioned at the face of the described side part of the described side part of described part, the described open end portion of the described U-iron heart, described top iron core of outer peripheral face of described coil of described open side of the described U-iron heart and described bottom iron core in abutting connection with described cooling-part.

5. calutron according to claim 4, wherein, a described face of described cooling-part is flat surface.

6. according to each described calutron in the claim 1 to 5, wherein:

Otch is arranged on the center of described side part of the described cooling-part of adjacency of described top iron core, and is positioned on the center line of opening of the described U-iron heart, and coil terminals is arranged on the part place of described coil; And

Described coil terminals is by described otch vertically extending upward along described center iron core.

7. calutron according to claim 6, wherein:

Recessed portion is arranged in abutting connection with the position of the described otch of described top iron core, and is positioned on the center line of described opening of the described U-iron heart; And

Fixed part is arranged in the female part.

8. according to each described calutron in the claim 1 to 7, wherein:

Be molded in the non magnetic plate on the iron core of described center, and the space bar that is used to keep interval width is arranged between the end in the vertical of the unshakable in one's determination and described center iron core in described top, and the space bar that is used to keep interval width is arranged between the other end in the vertical of the unshakable in one's determination and described center iron core in described bottom;

A described space bar and described center iron core corresponding to the described end setting in the vertical of described center iron core form; And

Another described space bar and described center iron core corresponding to the described other end setting in the vertical of described center iron core form respectively, are inserted in the iron core of described center to allow described coil.

9. calutron according to claim 8, wherein:

Mating part with the concavo-convex relationship cooperation is set on the unshakable in one's determination and described bottom iron core at each and described top of described space bar each other; And

Described top is unshakable in one's determination locatees with respect to described space bar by the cooperation of described mating part, and described bottom iron core is located with respect to described space bar by the cooperation of described mating part.

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