BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a configuration diagram showing Embodiment 1 of a block of wound core according to the present invention.
FIG. 2 is a configuration diagram of a transformer as an embodiment of the present invention.
FIG. 3 is an explanatory view of a wound core 4.
FIG. 4 is an explanatory view of a lap part 7 in the wound core 4.
FIG. 5 is a configuration diagram of a block of current wound core.
FIG. 6 is a configuration diagram showing Embodiment 2 of a block of wound core in the present invention.
FIG. 7 is a configuration diagram showing Embodiment 3 of a block of wound core in the present invention.
FIG. 8 is an overall configuration diagram of a manufacturing equipment in the present invention.
FIG. 9 is an explanatory view of a vapor deposition apparatus 12 in the present invention.
FIG. 10 is an explanatory view showing a general characteristic change for each manufacturing step of a single phase amorphous iron core transformer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, best mode embodiments of the present invention will be described using the accompanying drawings.
FIG. 2 is a configuration diagram of a transformer as a first embodiment of the present invention, FIG. 3 is an explanatory view of a wound core used in the transformer of FIG. 2, FIG. 4 is a schematic view of a lap part of an iron core, FIG. 5 is a configuration diagram within a block in the conventional amorphous iron core, FIG. 1, FIG. 6, and FIG. 7 are examples of forming an insulating thin film of an amorphous ribbon in the present invention, FIG. 8 and FIG. 9 are explanatory views concerning the manufacture of wound cores in the present invention and a method for forming the insulating thin film, and FIG. 10 is an explanatory view of a characteristic change in each manufacturing step of a single phase amorphous iron core transformer.
In FIG. 2, reference numeral 3 represents a pole transformer, reference numeral 4 represents a wound core for forming a magnetic circuit, reference numeral 5 represents an exciting coil for forming an electric circuit, and reference numeral 6 represents a container for mechanically protecting the transformer. For the wound core 4, as shown in FIG. 3 to FIG. 5 an amorphous ribbon 1 is laminated in a plurality of layers, which is referred to as a block 8, and by laminating this block 8 while displacing in the winding-around direction the wound core 4 is constituted. In the amorphous ribbon laminated in a plurality of layers, in the same block there exists a part that is formed from mutually abutting or overlapping the both ends, the part being referred to as a lap part 7. This is because the lap part 7 is opened to combine when inserting the wound core 4 in the coil 5.
Although the pole transformer is shown here, adaptation to the amorphous iron cores used in an oil immersed transformer and a molded transformer is also possible.
The present invention is characterized in that an insulating thin film is formed in the laminated amorphous ribbon, and as the formation of the insulating thin film, various kinds of forming patterns may be considered as shown in FIG. 1, FIG. 6, or FIG. 7. FIG. 1 is a case where an insulating thin film 2 is formed in both sides of each amorphous ribbon, wherein the space factor will decrease slightly while improvement in the iron loss characteristic is large. Moreover, FIG. 6 is a case where the insulating thin film 2 is formed in one side of each amorphous ribbon 1 and FIG. 7 is a case where the insulating thin film 2 is formed in one side of the outermost periphery of the block 8, wherein a decrease in the space factor is minimized while the characteristic improvement effect is small. In addition, a similar effect may be obtained also by forming the insulating thin film 2 in the most inner periphery of the block or in one side of the internal layer.
The thickness of the insulating thin film of the present invention is formed on the order of 1 μm while the thickness of the amorphous ribbon is typically on the order of 25 μm. It is preferable that the thickness of the thin film of this insulation material is as thin as possible so as to laminate the amorphous ribbon.
FIG. 8 shows a manufacturing equipment of the iron cores. The wound core 4 is pulled out of 10 amorphous ribbon material hoops 9, and is cut into a specified dimension at a cutting device 10, and is stacked by a conveying equipment 11 and is then wound around and shaped to manufacture. In the present invention, silane is vapor deposited on the surface of the amorphous ribbon with the deposition apparatus 12 in the step of pulling out the material from the amorphous ribbon material hoop 9 to the cutting device 10. In addition, although the material may be wound up from the material hoop 9 onto a material hoop again via the deposition apparatus 12 separately, and then be passed to the current wound core manufacturing equipment, it is preferable to employ the manufacturing equipment as shown in this figure, considering the manufacturing process.
FIG. 9 shows an embodiment of the deposition apparatus 12. The amorphous ribbon 1 enters a reaction chamber 13 that is partitioned from a partition 14 by a shielding layer 15, such as N2 or dry air. The amorphous ribbon 1 having entered the reaction chamber 13 follows a guide 18, and again, passes through the partition 14 and shielding layer 15 to go outside. At this time, the bottom of the reaction chamber 13 is filled with silane 16, which is evaporated with a heater 17. This evaporated silane 16 is vapor deposited onto the surface of the amorphous ribbon 1 to form the thin film. In this embodiment, the thin film is formed in the surface of one side of 10 sheets because 10 amorphous ribbon hoops 9 are passed therethrough at once. Accordingly, by dividing the guide 18 for each arbitrary number of sheets it is possible to form the thin film in any position.
In addition, the silane to vapor deposit is shown in Table 1. Materials of various kinds of composition system are applicable.
TABLE 1
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Various kinds of silane materials
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Representative chemical name
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Silane material
Structural formula
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Straight silicone oil
Dimethyl silicone oil
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system
Si(CH3)3—[SiO(CH3)2]N—Si(CH3)3
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Alkoxysilane system
Tetramethoxy silane
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Si(OCH3)4
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Next, the iron-loss reduction effect according to the present invention is described.
As shown in FIG. 10, at present state, the degradation rate, i.e., building factor, in the manufacturing process of amorphous iron core transformers is approximately 200% when turning the amorphous ribbon into a wound core, and this causes the characteristic degradation. This may be primarily because the lamination of the amorphous ribbons increases the apparent thickness and increases the eddy current loss.
Accordingly, by forming the insulating thin film in the surface of the amorphous ribbon of the present invention, an increase in the eddy current loss can be suppressed and no-load loss of the transformer can be reduced.
As the activities to preserve the earth's environment increase socially, it is requested to provide low-loss devices with regard to the power distribution equipment and materials, and the applicability of the present invention is extremely high.
It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
Patent Application
20080068121
