KR100388604B1 - Reactor having rectangular coil winded in elliptical edge-wise helicies and method of manufacturing thereof - Google Patents

Abstract

The present invention discloses a reactor having a flat coil wound with an elliptical cross winding halisis for use in direct current and alternating current circuits, and a method of manufacturing the same.

Reactor having a flat coil wound with an elliptical cross-border helisis according to the present invention is

An E-shaped multilayer iron core core comprising two outer legs and one central leg, and

Reactor comprising a flat coil for winding a flat copper wire in the form of an elliptical cross-border helisys, wherein the flat coil is inserted into the central leg of the core core.

Description

Reactor having a coil coiled with elliptic winding halixis and a method of manufacturing the same {REACTOR HAVING RECTANGULAR COIL WINDED IN ELLIPTICAL EDGE-WISE HELICIES AND METHOD OF MANUFACTURING THEREOF}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reactor (inductor, hereinafter referred to as a reactor) for use in direct current circuits and alternating current circuits, and more particularly, to reactors having a flat coil wound with an elliptical other winding halisis.

In general, a reactor is an electric or electronic device that exhibits great inductance against a sudden change in direct current or alternating current due to the accumulation of electromagnetic energy, and is generally a multilayer iron core as shown in FIG. A core reactor with a flat coil wound around the yoke core is used. An air core reactor (not shown) without an iron core core is also used.

Such a reactor may be configured as an open magnetic path or a close magnetic path depending on the flow type of the magnetic flux.

The reactor performance is determined by the effective distribution characteristics of the capacitance (capacitance), the frequency characteristics of the impedance, the skin effect at high frequency, the heat dissipation characteristics due to the convection of the windings, and the electrical characteristics that can withstand the overload.

The use of such reactors for motor-driven reactors or inverters in addition to power is increasing rapidly. Recently, various electronic devices tend to become high frequency gradually due to the development of inverter technology, and thus, electromagnetic interference, that is, EMI (Electro-) As regulation of magnetic interference is tightened, harmonics caused by the reactor, high frequency cut-off, and high frequency characteristics of the reactor have become more important.

However, conventional reactors for commercial frequency bands are increasingly difficult to meet these environmental requirements. In addition, in the case of the prior art, in addition to such a characteristic problem, it may be said to be an uneconomical method due to a problem in manufacturing cost.

Hereinafter, the structure of the conventional single-phase outer iron type and core reactor to waste is demonstrated with reference to FIG. 1 (a), FIG. 2 (a), and FIG. 3 (a).

1 (a), 2 (a), and 3 (a), reference numeral 1 denotes an upper yoke core of a reactor for forming a closed furnace, and this upper yoke core By removing the part 1, it is possible to form a reactor with individual pieces. Reference numeral 2 denotes a central leg of the E-shaped multilayer iron core yoke core 10, reference numeral 4 denotes an outer leg formed on both sides of the central leg, and reference numeral 3 denotes a central leg ( It is a rectangular strip coil (or a rectangular copper wire coil) which surrounds the exterior of 2). In general, in the electronic devices, copper wires having relatively low electric resistance are frequently used in consideration of electrical conductivity and economical aspects.

As shown in Fig. 2 (a), the flat coil 3 is generally wound three or five times in a wide width, or the wide width surface of the two or four layers of the multilayer flat coil 3 is formed of an iron core core ( On the wall surface of the central leg core 2 of 10), it can be wound and inserted in parallel with the axial direction. An insulating material is inserted between the multilayer coils 3 to be electrically insulated.

3 (a) is a longitudinal cross-sectional view taken along the line I-I of FIG. 1 (a).

Hereinafter, with reference to FIGS. 4 (a), 5 (a), 6 (a, b), 7 (a), 8 (a) and 9 (a), a reactor defining the performance of the reactor Heat dissipation characteristics, eddy current loss and circulating current loss characteristics, skin effect at harmonic and high frequency, workability, effective distribution value of capacitance, etc. will be described. In the reactor, when the effective distribution value of the capacitance becomes large, the resonance occurs at a predetermined frequency. Therefore, the reactor loses electrical characteristics above the resonance frequency, and thus the reactor cannot function.

FIG. 4 (a) is a cross-sectional view of the reactor taken along line A-A in the outline view of the conventional reactor shown in FIG. 1 (a).

In Fig. 4 (a), the upper yoke core portion 1 is joined on the E-shaped multilayer iron core yoke core 10 to form a closed reactor. An insulating material is inserted between the E-shaped multilayer iron core yoke core 10 and the upper yoke core portion 1 to provide a gap 5 of an appropriate thickness.

In addition, as shown in FIG. 4A, an insulating material 7 is inserted and insulated between the center leg portions 2 of the iron core yoke core 10. Flat coils 3 The flat coils 3, for example three layers, are insulated by inserting an interlayer insulating material 6 between the layers. The winding of such a flat coil has a considerable potential difference between adjacent coil layers, and also the interlayer insulating material 6 should always be put in place because the edges of the flat coil may be staggered at each other in the part of the layer change during the winding, which may break the insulation.

Therefore, in the case of such a conventional reactor, as shown in Fig. 5 (a), only a part of the flat coil 3 is naturally cooled by natural convection (CA) in direct contact with the outside air. In other words, the flat coil shown in white in FIG. 5 (a) is in direct contact with outside air, but heat generated in the inner flat coil shown in black in FIG. 5 (a) is sealed and does not radiate heat.

Therefore, the average temperature of the whole winding rises, and in order to prevent this, it is necessary to use a copper wire of a larger cross-sectional area or to create a separate air duct between the layers. Work will follow.

Therefore, there is a problem that the manufacturing time is increased and the manufacturing cost is greatly increased due to such various additional operations and the use of the interlayer insulating material 6 or the use of copper wire having a large cross-sectional area.

On the other hand, when only the copper wire having a large cross-sectional area is used in consideration of the temperature rise inside the reactor as described above, as shown in FIG. 6 (a), Eddy-loss and Circulating current loss increases rapidly. In addition, when the cross-sectional area is increased by such a single copper wire, the current is concentrated only on the outside at harmonics and high frequency, that is, the skin effect is increased, and thus the effective resistance of the copper wire increases dramatically. On the contrary, the loss of the reactor itself is increased, resulting in a severe temperature rise.

In the case of such a conventional reactor, the following description will be given with reference to Figs. 6 (a, b) due to the characteristics of the winding operation (the problems caused by the lead extraction and the winding).

In FIG. 6 (a), since the ratio (W / t) of the width W and the thickness t of the flat coil is usually in the range of 2 to 4, when the flat coil is selected in consideration of workability, harmonics and It is very difficult to avoid problems such as the skin concentration and the eddy current loss at the high frequency where the current is concentrated only outward. Therefore, there are many limitations in using the conventional harmonic and high frequency circuits.

In order to prevent this phenomenon, as shown in Fig. 6 (b) may be used in combination with a flat coil of several strands, Figure 6 (b) shows the case of using four strands as an example, in this case, winding in the direction of the arrow In the case (when each of the flat coils a, b, c, d) (hereinafter referred to as "element wires") are wound in a radial direction, the element wires a, b have the same overall length and thus the "element wires (c, d) ) Also have the same resistance value, but since the wires (a, b) and the wires (c, d) have different lengths of the flat coils, the resistances are different. That is, the element wire wound from the outside has a longer length than the element wire wound from the inside, thereby increasing the resistance value. In addition, since the geometric mean distance between the element wires in the radial direction is different, a circulating current is generated inside the flat coil due to leakage magnetic flux generated from the reactor itself.

Therefore, in order to solve these two problems, it is necessary to perform a transposition operation in which the positions of the respective wires are interchanged.

There are various methods of dislocation work depending on the number of wires, and it is very difficult for a large reactor not to have a cross section between wires, and to break and insulate a flat copper wire several times.

Hereinafter, with reference to FIG. 7 (a), the effective distribution of the capacitance of the conventional reactor is demonstrated.

Fig. 7A is a diagram showing an effective distribution of capacitance of a winding in a conventional winding of a multilayer flat coil.

In FIG. 7A, the distribution of the capacitance of the winding of the flat coil 3 is the capacitance Cc between the winding of the flat coil 3 and the center leg 2 of the core and the flat coil 3. There is a capacitance Ct between the layer and the layer of layers Cl and the number of turns of the flat coil. Since such capacitance is very complicated, it can be briefly expressed as the capacitance of the entire winding coil as follows.

First, the capacitance Cc between the center leg of the core and the first flat coil layer can be expressed by the following equation.

Cc = (0.0089 * MLT * ST * ε) / d

Where MLT: average winding length, ST: winding length, ε: dielectric constant, d = insulation distance (insulation material thickness).

Second, the effective distribution of the capacitance (Cp) of the entire winding can be represented by the following equation.

Cp = (4 * Cc / 3 * NL) * (1- 1 / NL)

Where NL is the number of layers in the flat coil

The capacitance Cc has to increase the insulation distance d, reduce the average length MLT and winding length ST of the winding, and use an insulation material having a low dielectric constant ε.

The dielectric constant (ε) of most insulating materials has a value of about 2 to 5 (see Table 1 of dielectric constant), and the average length, length, and insulation distance of the winding in consideration of economic efficiency, dimensions, workability, and safety. It is very difficult to make it ideal.

Vaccum 0.0885PF / c FIBER 5 Transformer Oil (OT) 2.2 MYLAR 3.3 Press Board (PB) 4.5 Kapton 3.5

(Table 1) Dielectric constant table

It is also impossible to reduce the capacitance by increasing the number of layers of the winding in the calculation formula of the capacitance Cp.

In low current reactors (up to a few amps), the capacitance can be reduced by progressive, banked, sectioned windings, etc. Ampere-type reactors are very difficult to apply in a special way in addition to conventional windings.

In FIG. 7 (a), the capacitance Ct between the turns of the windings is formed between the turns of the windings of the same layer and the turns of the windings of another layer, so that the capacitance between turns is directly and in parallel. It is complicated and in the case of multilayers, the capacitance of the winding is usually very large compared to the capacitance Ct between the turns of the winding.

In particular, when the number of layers of the flat coil is even (2, 4, 6 layers), the start and end portions are close to each other, and the capacitance of the entire winding is very large.

The capacitance of this winding limits the range in which the reactor operates as a reactor. If the inductance of the reactor is L and the capacitance is C, the reactor has a resonance frequency (Fr) point.

The resonance frequency Fr can be expressed by the following equation.

Fr = 1 / 2p (LC) 1/2

That is, the reactor operates as a reactor (inductor) below the resonance frequency, but loses the characteristics as a reactor above the resonance frequency.

The present invention is excellent in workability, which solves the problems of workability, economical efficiency, high frequency characteristics, capacitance characteristics, etc., which are all disadvantages of the prior art, and reduces the effective distribution of capacitance formed in the reactor, thereby making the high frequency characteristic of impedance significant. To improve the electrical characteristics and reduce the material of the copper coil by reducing the skin effect at high frequency, maximizing heat dissipation due to the natural convection of the coil winding, and increasing the overload resistance. .

1 (a) is an external view of a reactor having a conventional multilayer flat coil,

Figure 1 (b) is an external view of a reactor having a flat coil wound with an elliptical winding another helisis according to an embodiment of the present invention,

Figure 2 (a) is an exploded perspective view of the conventional reactor shown in Figure 1 (a),

Figure 2 (b) is an exploded perspective view of the reactor according to the present invention shown in Figure 1 (b),

FIG. 3 (a) is a longitudinal sectional view of the reactor taken along line I-I in the outline view of the conventional reactor shown in FIG. 1 (a);

Figure 3 (b) is a longitudinal cross-sectional view of the reactor cut along the line II-II in the outline of the reactor according to the present invention shown in Figure 1 (b),

4 (a) is a cross-sectional view of a reactor taken along line A-A in the outline of the conventional reactor shown in FIG. 1 (a),

4 (b) is a cross-sectional view of the reactor cut along the line B-B in the outline of the reactor according to the present invention shown in FIG. 1 (b),

FIG. 5 (a) is a partial cross-sectional view for explaining heat dissipation of the conventional multilayer flat reactor shown in FIG. 4 (a);

5 (b) is a partial cross-sectional view for explaining the heat dissipation of the reactor of the present invention shown in FIG. 4 (b),

6 (a, b) is a view for explaining the eddy current loss and corridor relationship in the copper coil of a conventional reactor,

Figure 6 (c, d) is a view for explaining the in-line eddy current loss and corridor relationship of the reactor of the present invention,

7 (a) is a cross-sectional view for explaining the distribution of capacitance in a winding of a conventional reactor;

Figure 7 (b) is a cross-sectional view for explaining the capacitance distribution in the winding of the reactor of the present invention,

8 is a graph of "Inductance vs. Frequency Characteristics of Reactor Furnace" for comparing the frequency characteristics of inductance when the prior art and the method of the present invention are applied to the individual furnace;

FIG. 9 is a graph of "impedance vs. frequency characteristic of reactor with the reactor" for comparing the frequency characteristics of the impedance when applying the prior art and the scheme of the present invention to the reactor.

<Explanation of symbols for the main parts of the drawings>

1: upper yoke core 2: center leg of the yoke core

3: flat coil 4: outer leg of yoke core

5: gap 6: interlayer insulation of flat coil

7: Inner insulation of flat coil 10: E-shaped multilayer iron core yoke core

B: radial thickness of coil winding ST: axial length of coil winding

MLT: Average length of coil winding CW: Window width of yoke core

CS: Core lamination thickness of yoke core WH: Window height of yoke core

l _m : Average magnetic field _{length of} yoke core e: Voltage applied to reactor (terminal voltage)

I: Current flowing through coil winding R: Resistance of coil winding

N: Number of turns of coil winding F: Magnetic flux flowing in yoke core

NL: number of layers of coil winding CA: convection around coil windings

W: Width of copper winding for coil winding t: Thickness of copper winding for coil winding

Cc: capacitance between coil winding and yoke core

Cl: Interlayer capacitance of coil winding Ct: Interturn capacitance of coil winding

Fr: resonant frequency Cp: effective capacitance of coil winding

f: frequency L: inductance

Z: Impedance A _c : Effective cross section of yoke core

B: magnetic flux density of yoke core ε: dielectric constant of insulating material

H: strength of magnetic field in reactor

According to one embodiment of the present invention, a reactor for use in DC and AC circuits,

An E-shaped multilayer iron core core comprising two outer legs and one central leg, and

Flat coil by winding flat copper wire in the form of oval cross-border halisys

It includes, characterized in that the flat coil is inserted into the central leg of the core core.

The reactor may be configured as a closed type system, or further including an upper yoke core to configure a closed type system.

According to another embodiment of the present invention, a method for manufacturing a reactor for use in direct current and alternating current circuits, comprising an E-shaped multilayer iron core core comprising two outer legs and one central leg, and a flat coil,

Winding the wide face of the flat coil into an oval shape perpendicular to the axial direction and winding in an elliptical other winding helical structure as a whole; and

And inserting a flat coil wound with the elliptical cross winding halisis into a central leg of the core core.

(Example)

Hereinafter, a reactor according to an embodiment of the present invention will be described in detail with reference to FIGS. 1 (b), 2 (b) and 3 (b).

Figure 1 (b) is an external view of a reactor having a flat coil coiled with an elliptical winding another helisis according to an embodiment of the present invention, Figure 2 (b) is an exploded perspective view of the reactor shown in Figure 1 (b) 3 (b) is a longitudinal cross-sectional view taken along the line II-II of the reactor according to the present invention shown in FIG. 1 (b).

In Fig. 1 (b), for convenience of explanation, the same reference numerals are given to the same components as those shown in Fig. 1 (a), and terms and the like are not particularly defined.

In other words, the upper yoke core portion 1, the E-shaped multilayer iron core yoke core 10, the center leg portion 2 of the iron core yoke core 10, and the two outer leg portions 4, and the upper yoke core portion The gap 5 by the insulating material inserted between (1) and each leg part 2 and 4 is as showing to FIG. 1 (a).

The flat coil 3 wound by the elliptical cross-border halixi of the reactor according to the embodiment of the present invention is generally made of a copper wire coil 3. However, it should be appreciated that it is not limited to copper wire coils.

However, the flat coil used in the reactor according to the present invention winds the flat copper wires of FIGS. 2 (b) and 3 (b) in the form of elliptical edge-wise helicies. Here, the elliptical other winding halisis is different from the method of bending the wide surface of the flat copper coil commonly used in the conventional reactor in the axial direction, and by bending the narrow surface of the flat copper coil in the axial direction, the wide of the flat copper coil The surface is placed perpendicular to the axial direction and refers to a spiral winding method as shown in FIG. 2 (b) as a whole. Looking at this winding method, as shown in Figure 3 (b) takes the form of a track of the stadium. In the following, this is simply referred to as a flat coil 3 wound with an ellipsoidal winding halisys.

The flat coil 3 wound by this elliptical winding halisis is inserted into the center leg 4 of the E-shaped iron core yoke core 10, as shown in FIG. Inserting the flat coil 3 wound with an elliptical winding halisys and assembling the upper yoke core portion 1 by inserting an insulation material at each leg end of the iron core yoke core 10 is the same as that of a conventional reactor. .

Hereinafter, with reference to Figure 4 (b), Figure 5 (b), Figure 6 (c, d), Figure 7 (b) with respect to the characteristics of the reactor having an elliptical winding Helicis flat coil according to the present invention; Explain.

First, in order to explain the reactor characteristics of the present invention in detail, the reactor principle is briefly introduced with a formula,

First, according to Faraday's law, the reactor's voltage (terminal voltage can be calculated by the following equation.

e =% IX = L (di / dt) = N (dΦ / dt)

LI = NΦ = NBA _C ... Equation 1

Where e: reactor voltage (terminal voltage),% IX:% reactance drop, di / dt: rate of change of current (differential), N: number of turns of reactor winding, dΦ / dt: rate of change of magnetic flux (differential), L: inductance, I: current, B: magnetic flux density, A _C : effective cross-sectional area of the core.

Also, in Ampere Law, the following equation holds.

H l _m = NI. Equation 2

Where H is the strength of the magnetic field, l _m is the length of the path, N is the number of turns of the reactor winding, and I is the current.

In equation 1), LI = NBA _c → I = NBA _c / L, multiply both sides by N,

NI = N ² BA _C / L is derived. Substituting this in equation 2),

H l _m = NI = N ² BA _c / L, and B = μ ₀ μ _σ H

therefore,

L = N ² BA _c / H _m = μ ₀ μ _σ N ² A _c / l _m . Expression 3

This equation 3) is a case where there is no gap 5, and in the case of a reactor in which the gap 5 is inserted, the following equation is established.

L = (0.4 πA _c N ² * 10 ^-8 ) / (l _g + l _m / μ _σ )

Where l _g : length of the gap 5, μ _σ : relative permeability of the core, μ ₀ : permeability in vacuum = 0.4 π * 10-8

In the above equation, it can be seen that the inductance L of the reactor is proportional to the product of the square of the turn number N of the winding coil and the cross-sectional area A _c of the core and is inversely proportional to the length of the gap l _g .

In the case of the present invention, since the winding coil is an elliptic structure as shown in FIG.

That is, it has a wide range of core selection phases, which is an advantage of the prior art.

In the equation, if the number of turns N of the windings is increased, the magnetic flux density of the core is reduced, and the noise problem and the core loss are reduced. However, it can be seen that the inductance L is increased.

Therefore, in order to obtain a predetermined inductance L, since the inductance L is inversely proportional to the length l _{g of the} gap 5, the length of the gap 5 must be increased to an appropriate value.

Therefore, in this case, another problem arises, such as the need to divide the gap 5, and when the gap is large as one place, a magnetic flux enlargement phenomenon occurs and the loss rapidly increases, and the inductance value is calculated. The result does not fit well with.

The length of the furnace (l _m ) and the length of the gap (5) are selected according to the HANA Method (Design of Reactances Transformer which carry direct current .-- CR HANNA). In the case of using, since the size of the window that the copper wire (winding) can enter from the core is constant, the number of turns of the winding is very limited in consideration of the magnitude of the current. Therefore, it is a great advantage to be able to freely select the cross-sectional area of the core in the reactor.

Therefore, in the case of the present invention has the advantage as it is, while having the advantages as the technology on the winding.

Hereinafter, various characteristics of the reactor according to the exemplary embodiment of the present invention will be described with reference to FIGS. 4B, 5B, 6C, and 7B.

As shown in FIG. 4 (b), the reactor according to the embodiment of the present invention is wound so that the width of the copper wire is parallel to the radial direction. Therefore, in order to wind a predetermined number of turns, a thin coil having a wide thickness and a wide width as shown in FIG. 6 (c) are used, which is ideal for reducing eddy current loss, circulating current loss, and skin effect of copper wire in copper wire. .

In addition, as shown in Fig. 6 (d), since the corridor is used in parallel, it is not necessary to perform a separate transposition work, and it can be seen that the manufacturing workability of the reactor is significantly increased.

As shown in Fig. 6D, the element wires a, b, c, and d are configured in parallel and are wound in the winding direction (radial direction), and thus have the following characteristics.

First, as compared with the conventional reactor shown in Figs. 6A and 6B, each element wire has the same average length (length), and therefore, each element wire resistance is the same. Therefore, there is no loss due to the potential difference between element wires.

Second, since the geometric distance is maintained equal to the leakage magnetic field, the circulating current loss in the element wire generated in the direction of canceling the change of the magnetic field is extremely small. Therefore, in the case of the present invention, there can be almost no loss other than pure copper loss by the load current. Therefore, it is very excellent in terms of loss and can be a high efficiency device.

That is, in the reactor according to the present invention, since the width of the copper wire selection becomes very wide according to the magnitude of the current, it is more effective than the conventional case.

FIG. 5 (b) is for explaining the cooling effect due to the natural convection CA of the reactor. In FIG. 5, since all parts of the flat coil 3 are naturally convection in contact with air, It is understood that the cooling effect is very excellent even without providing a separate cooling passage like the conventional reactor shown.

The temperature rise value θ in the winding excluding the general ambient temperature can be expressed by the following equation.

θ = K * (Wcu / Sc) ^0.8

Where θ: temperature rise value, K: constant according to ambient temperature and core structure, Sc: heat dissipation area in winding, Wcu: loss

This equation assumes the same heat dissipation conditions for the inner and outer copper wires of the winding. That is, in the conventional reactor, the inner flat coil and the outer flat coil cannot have the same heat dissipation condition and thus cannot have the same temperature rise value. In the case of the heat dissipation area Sc and the total loss Wc of the winding being the same, and assuming that the parameter K is the same as the core shape and other external conditions are the same, in the case of the present invention, it is shown in FIG. As such, the entire flat coil of the reactor is in contact with natural cooling convection (CA), so that there is no local hot spot that may occur in one part of the winding. That is, it can be seen that all the copper wires have the same heat dissipation state, and it can be seen that the temperature rise of the average winding is lower than that of the prior art in the whole winding.

Therefore, in the prior art, since the inner copper wire (black display in Fig. 5A) can hardly radiate heat, the temperature rise of the actual winding is increased.

Looking at the "thermal conductivity table" shown in Table 2 below, the insulating material except for non-ferrous metals such as aluminum, copper, silver, and the like has a very low thermal conductivity. Therefore, in the case of the prior art, the inner copper wire is very difficult to dissipate due to the interlayer insulating material and the outer copper wire.

Aluminum (Al) 5.14 W / (in, 0C) Copper 9.76 Silver 10.7 Kraft paper 0.003 Fiber 0.007 Polyester film 0.004 Air 0.00075

(Table 2) Thermal conductivity comparison table

This heat dissipation property is very important to reduce the manufacturing cost of the reactor. As a result of the test, the temperature rise in the reactor according to the present invention can satisfy the prescribed temperature rise even if a current of + 25% is further flowed than in the case of the conventional reactor using the flat coil having the same cross-sectional area.

That is, since 1 / 1.25 = 0.8, the weight of the flat coil used in the reactor according to the present invention can be reduced by 20% than in the conventional case. Therefore, the reactor according to the present invention can produce a very economical product.

On the other hand, the reactor according to the present invention can be seen that the durability is very high because the overload resistance is excellent based on the same cross-sectional area.

Hereinafter, the effective distribution of the capacitance of the reactor according to the present invention will be described with reference to FIG. 7B.

7 (b) is a cross-sectional view for explaining the distribution state of the capacitance in the reactor of the present invention.

In Fig. 7 (b), the capacitance of the coil winding itself is only the capacitance Ct between turns of the coil. In addition, since the capacitance Ct between turns is entirely connected in series, in the present invention, the capacitance Cp of the whole winding can be simply expressed by the following equation.

Cp = Ct / N, where N is the number of turns and Ct is the capacitance between turns

Thus, the distribution capacitance of the windings of the reactor according to the invention is very small.

That is, since the reactor of the present invention has a higher resonance frequency (Fr) than the reactor according to the prior art, it can be seen that the operating range in the reactor is very large.

Hereinafter, the distribution value of the capacitance in the reactor according to the present invention and the conventional reactor will be described.

As mentioned above, the effective distribution value of the capacitance in the conventional reactor is as follows.

Cp = (4 * Cc / 3 * NL) * (1- 1 / NL),

Here, NL is generally three to four layers as the number of layers of the coil winding, and therefore, when NL, i.e., the maximum number of layers is assumed to be four layers, the effective distribution value of the capacitance is

Substituting NL = 4 into the above equation,

Cp = 0.25 * Cc

That is, even if the minimum value is assumed, the effective distribution of the capacitance is 25% of the capacitance Cc of the central leg of the iron core yoke core 10 and the first layer of the winding coil 3.

On the other hand, the effective distribution value of the capacitance in the reactor according to the present invention is

Cp = Ct / N,

Where N = number of turns, Ct = capacitance between turns

N, that is, the number of turns is four to seven times the NL value for reactors of the same structure, capacity and dimensions.

N = 4 * NL (assuming minimum value)

Cp = Ct / 4 * NL, (N: number of turns), (Ct = capacitance between turns)

If NL = 4 under the same conditions as the conventional reactor,

Cp = Ct / 16 = 0.0625 Ct

In addition, since the value of the capacitance Ct between the coil turns is much smaller than the value of the capacitance Cc between the yoke core and the winding due to the structure of the reactor, the effective distribution value Cp of the capacitance of the conventional reactor = 1 Assuming

The capacitance distribution value Ct in the reactor of the present invention is 0.25 Cp or less.

That is, it can be seen that the structure that can lower the effective distribution of the capacitance at least 75% or more than the conventional reactor.

(Example of actual calculation)

The actual calculation of the effective distribution value of the capacitance in the reactor according to the present invention and the conventional reactor will be described below.

In fact, the actual calculations for the reactor with DC 94A and 0.4mH ripple frequency 360HZ,

Cc = (0.0089 * MLT * ST * ε) / d

Where MLT: winding average length, ST: winding length, ε: dielectric constant, d = insulation distance (insulation material thickness).

Cc = (0.0089 * 290 * 4 * 3.0) /0.2 = 154.86 PF

Cp = (4 * Cc / 3 * NL) * (1- 1 / NL) = (4 * 154.86 / 3 * 4) * (1- 1/4)

= 38.715 PF

On the other hand, in the case of a reactor according to the present invention

Ct = ε _O * S / d = 0.0885 * 30.42 / 0.05 = 53.8 PF

(MLT = 2 * 105 * +2 * π * 15 = 304.2mm)

therefore,

Cp = Ct / N = 53.8 / 13.5 = 3.9884 PF

Here, S is a charge area between turns, S = 30.42Cm ² , ε _O is 0.0885PF / Cm in air, and a pitch of 0.5 mm is applied.

If the calculation reflects the actual permittivity or structure as above, it can be seen that the distribution value of the capacitance is further different.

(Comparison of the high frequency characteristics of the reactor type reactor)

Hereinafter, with reference to FIG. 8, the high frequency characteristic of the reactor by an individual method is demonstrated.

8 is a comparative test of the characteristics of the inductance (L) value according to the frequency of the reactor having a conventional reactor and the elliptical cross-circulation helical coil winding of the present invention in the case of the open-air method.

Here, the experiment is a result made by the impedance analyzer according to the reactor equivalent circuit.

In the conventional reactor indicated by the dotted line in FIG. 8, resonance occurs at a frequency of about 5.7 MHz, but it can be seen that the reactor of the present invention indicated by the dotted line in FIG. 8 causes resonance in about 20 MHz.

This shows the inductance (L) characteristics according to the frequency, the reactor of the present invention causes resonance at about 20 MHz. That is, it operates as a reactor up to 20 MHz, which is very important in winding characteristics. That is, the conductive noise in the power line is less than 10 MHz in the harmonic range, so the characteristics of the winding coils are normal and common mode reactors (inductors) of the power filter in addition to the commercial frequency. ) Shows sufficient usable performance.

In particular, the characteristic shown in Fig. 8 is that a silicon steel sheet for commercial frequency is used, and when a ferrite or the like for high frequency material is used, it has sufficient performance as a high frequency reactor.

Due to the characteristics of the open reactor reactor, leakage flux occurs at the end of the furnace, but its use range is limited, but it has better saturation characteristics than the reactor reactor, and the series inductance (Ls) and series resistance (Rs) at high frequencies are higher. It is used to suppress surge voltage by using) characteristic.

Conventional reactors have a disadvantage in that they are difficult to maintain characteristics at high frequencies.

The resonance phenomenon is due to the distribution capacitance of the reactor winding, which means that the winding capacitance is large because the resonance occurs in the low frequency region in the conventional reactor technology.At the above 5.7 MHz, the characteristics of the reactor lose the characteristics as the reactor and operate like capacitance. It means.

Therefore, conventional reactors are very unsuitable for inductors (reactors) used in filters for inverters and other power lines.

(Comparison of High Frequency Characteristics of Reactor Type Reactor)

Hereinafter, with reference to FIG. 9, the high frequency characteristic of the reactor of a closed type system is demonstrated. Figure 9 shows the characteristics according to the frequency of the impedance (Z) in the case of applying the method to the closed. The reactor used was a DC 94A, 0.4mH, ripple frequency 360HZ reactor.

The impedance characteristics of the conventional reactor and the reactor of the present invention when the same conditions, the same number of turns, and the same core size are the same are shown.

Here, the experiment was performed using an impedance measuring device according to the reactor equivalent circuit, and the results are shown in FIG. 9.

In the ideal case, the high frequency characteristic has no distribution of the capacitance of the winding, and the impedance (Z) characteristic continuously increases to Z = 2 * p * f * L with increasing frequency. However, in practice, the winding capacitance causes resonance at a predetermined frequency. In the conventional reactor, the resonance occurs at about 3.3 MHz, and in the present invention, at about 7 MHz.

This high frequency characteristic is that the reactor of the present invention operates as a reactor in more than twice as large area as the conventional reactor.

As shown in FIG. 9, in the case of the present invention, resonance occurs at about 7 MHz, which is very effective for attenuating conductive noise generated in an inverter.

In addition, the reactor according to the present invention having such characteristics can be widely used in direct current, commercial frequency, and high frequency regions only by changing the material of the core.

In the case of a closed reactor, the reactor has a large inductance value, and the leakage magnetic flux is extremely low, so it is often used in an electronic device.

With the recent development of inverter technology, high frequency devices are gradually increased and electromagnetic interference, ie, electromagnetic-magnetic interference (EMI) regulation, is strengthened. Therefore, it requires more and more harmonics by the reactor, high-frequency blocking method, and high-frequency characteristics of the reactor. In the conventional commercial frequency band reactor, it is increasingly difficult to meet such environmental requirements.

In addition to these problems, the prior art may be called an uneconomical method due to manufacturing cost.

Therefore, in the case of the conventional reactor, application is very limited and inefficient except for the commercial frequency.

On the other hand, the reactor according to the present invention can find such low distributed capacitance characteristics and important application method in the above formula.

As shown in (b) of FIG. 7, the coil windings are grouped (sectioned) without uniformly winding to further separate the groups, and in FIG. 7 (b), when the proper spacing (pitch) is provided between the element wires, Since the capacitance between turns decreases in inverse proportion to the interval, the overall effective capacitance can be made very small.

And unlike in Figure 1 (b), that is, when manufactured by separating the two windings in the core structure (Core structure, not shell structure), the value of the distribution capacitance of the winding is smaller than the relation value in the equation Since the reactor according to the present invention may have a very high frequency characteristic than that of the conventional reactor, the reactor according to the present invention has a very efficient characteristic for devices such as various inverters which have recently been high frequency.

According to the reactor according to the present invention, it is a reactor used for direct current and alternating current circuit, and particularly, the coil winding inner cross section is wound in an elliptical edge-wise helical manner, thereby producing the following effects.

First, through the reduction of the effective distribution of capacitance, the frequency characteristics of impedance are greatly improved compared to conventional reactors, and the resonant frequency is extended by about 3 times or more in the open circuit method and about 2 times or more in the closed circuit method. It can be operated as a reactor in a wide frequency band.

Second, it is possible to structurally maximize the heat dissipation by the convection of the coil winding, it is possible to reduce the weight of the copper wire by about 20% or more under the same conditions.

Third, all electrical properties are improved by reducing the skin effect and increasing the overload resistance at high frequency.

Claims (4)

In reactors used for direct current and alternating current circuits, An E-shaped multilayer iron core core comprising two outer legs and one central leg, and Flat coil wound flat copper wire in the form of oval cross-border halixis And the flat coil is inserted into a central leg of the core core. The method of claim 1, further comprising an upper yoke core, Reactor characterized in that the reactor constitutes a waste. An E-shaped multilayer iron core core comprising two outer legs and one central leg, and In the method of manufacturing a reactor comprising a flat coil, used for direct current and alternating current circuit, Winding the wide face of the flat coil into an oval shape perpendicular to the axial direction and winding in an elliptical other winding helical structure as a whole; and Inserting a flat coil wound with the elliptical winding halisys into a central leg of the core core; Reactor comprising a. delete