Core main body, reactor, and method of manufacturing reactor

Patent metadata

Field	Value
Publication number	US-11600424-B2
Application number	US-202016908889-A
Country	US
Kind code	B2
Filing date	Jun 23, 2020
Priority date	Jul 3, 2019
Publication date	Mar 7, 2023
Grant date	Mar 7, 2023

Abstract

A core main body includes an outer peripheral iron core, and at least three iron cores. Between the two iron cores adjacent to each other, a gap being magnetically couplable is formed. The outer peripheral iron core includes a first outer peripheral iron core block and a second outer peripheral iron core block that are formed by stacking a plurality of magnetic plates, and an intermediate plate disposed therebetween. The intermediate plate includes an outer peripheral iron core corresponding portion corresponding to the outer peripheral iron core, a plurality of protruding sections protruding from an outer peripheral surface of the outer peripheral iron core, and engaging sections provided on the plurality of protruding sections.

First claim

The invention claimed is:

1. A core main body comprising:
an outer peripheral iron core;
at least three iron cores disposed inside the outer peripheral iron core; and
a coil mounted on each of the at least three iron cores, wherein
a radial inner end portion of each of the at least three iron cores converges toward a center of the outer periphery iron core,
a gap being magnetically couplable is formed between one iron core of the at least three iron cores and another iron core adjacent to the one iron core, and the radial inner end portions of the at least three iron cores are spaced apart from each other through the gap being magnetically couplable,
the outer peripheral iron core is configured with at least a first outer peripheral iron core block formed by stacking a plurality of magnetic plates, a second outer peripheral iron core block formed by stacking a plurality of magnetic plates, and an intermediate plate disposed between the first outer peripheral iron core block and the second outer peripheral iron core block, and
the intermediate plate includes an outer peripheral iron core corresponding portion corresponding to the outer peripheral iron core, a plurality of protruding sections protruding from an outer peripheral surface of the outer peripheral iron core, and engaging sections provided on the plurality of protruding sections, wherein
a position of the engaging sections in an axial direction of the core main body is approximately equal to a position of a center of gravity of the core main body.

2. The core main body of claim 1 , wherein
the first outer peripheral iron core block and the second outer peripheral iron core block are configured with a plurality of outer peripheral iron core portion blocks and
the intermediate plate is configured with a plurality of intermediate plate portions corresponding to the respective plurality of first outer peripheral iron core portion blocks.

3. The core main body of claim 1 , wherein
the intermediate plate further includes iron core corresponding portions corresponding to the at least three iron cores.

4. A reactor comprising:
the core main body according to claim 1 ; and
a pedestal attached to one end of the core main body.

5. The reactor of claim 4 , wherein
the number of the at least three iron core coils is a multiple of three.

6. The reactor of claim 4 , wherein
the number of the at least three iron core coils is an even number being equal to or more than four.

7. A method of manufacturing a reactor comprising steps of:
stacking a plurality of magnetic plates and forming a plurality of first outer peripheral iron core portion blocks;
stacking a plurality of magnetic plates and forming a plurality of second outer peripheral iron core portion blocks;
preparing a plurality of intermediate plate portions corresponding to the respective plurality of first outer peripheral iron core portion blocks;
disposing each of the plurality of intermediate plate portions on each of the plurality of first outer peripheral iron core portion blocks;
disposing each of the plurality of first outer peripheral iron core portion blocks on each of the plurality of intermediate plate portions and forming a plurality of outer peripheral iron core portions including at least three iron cores, wherein a position of engaging sections of the plurality of intermediate plate portions in an axial direction of the reactor is approximately equal to a position of a center of gravity of the reactor;
mounting a coil on each of the at least three iron cores;
assembling the plurality of outer peripheral iron core portions together and forming a core main body; and
attaching a pedestal to one end of the core main body and securing the core main body and the pedestal to each other.

Assignees

• Fanuc Corp

Inventors

• Yoshida Tomokazu

Classifications

• H01F27/306

  Fastening or mounting coils or windings on core, casing or other support · CPC title

• H01F27/24 Primary

  Magnetic cores · CPC title

• H01F41/0233

  Manufacturing of magnetic circuits made from sheets (magnetic cores made from sheets H01F27/245; soft magnetic alloys in the form of sheets H01F1/16) · CPC title

• H01F41/0206

  Manufacturing of magnetic cores by mechanical means (magnetic cores per se H01F27/24) · CPC title

• H01F3/14 Primary

  Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12) · CPC title