Magnetically coupled reactor and power converter

• US 9,570,995 B2
• Filed: 09/09/2015
• Issued: 02/14/2017
• Est. Priority Date: 09/17/2014
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Inoue, Shuntaro, Sugai, Masaru, Takagi, Kenichi, Sugiyama, Takahide, Nagashita, Kenichiro, Tanahashi, Fumiki
• Primary Examiner(s): Berhane, Adolf
• Application Number:
  US14/848,910
• Publication Number:
  US 20160079873A1
• Time in Patent Office: 524 Days
• Field of Search: 336/60, 336/65, 336/83, 336/84.C, 336/196, 336/214, 336/221, 336/232, 363/15, 363/17, 363/37
• US Class Current: 1/1
• CPC Class Codes: H01F 27/245 made from sheets, e.g. grain-oriented H01F27/26 takes precedence
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H02M 1/009 having two or more independently controlled outputs for DC-DC converter with intermediate AC H02M3/33561
• CPC Class Codes: H02M 1/0095 Hybrid converter topologies, e.g. NPC mixed with flying capacitor, thyristor converter mixed with MMC or charge pump mixed with buck
• CPC Class Codes: H02M 1/123 Suppression of common mode voltage or current
• CPC Class Codes: H02M 3/158 including plural semiconductor devices as final control devices for a single load
• CPC Class Codes: H02M 3/33546 with automatic control of the output voltage or current H02M3/33561 takes precedence
• CPC Class Codes: H02M 3/33584 Bidirectional converters
• CPC Class Codes: H02M 3/3372 of the parallel type

Abstract

A magnetically coupled reactor includes a coupled core member, a first coil, and a second coil. The coupled core member includes a first core and a second core made of a magnetic material and disposed to face each other, a coil channel, and a sheet-like magnetic body by which a coupling portion between cores is put between the first core and the second core at an outer portion of the first and second cores. Each coil is wound around a leg through the coil channel in a lap winding manner such that the coils are overlapped on top of each other in the coil channel when seen in an axial direction. The sheet-like magnetic body extends from the coupling portion between coils into the coil channel and includes a portion arranged between coils located between the coils in the axial direction.

Claims

1. A magnetically coupled reactor, comprising:

a coupled core member; and

a first coil and a second coil,

the coupled core member including

a first core and a second core made of magnetic materials and arranged to face each other,

a coil channel formed by a recess formed between two legs on a side facing the first core and the second core, and

a sheet-like magnetic body by which a coupling portion between cores is put between the first core and the second core on a peripheral side at an outer portion formed by one of the two legs,

the first coil and the second coil passing through the coil channel and being wound around the other of the two legs and being overlapped alternately in the coil channel when seen in an axial direction, wherein

the sheet-like magnetic body has a portion arranged between coils that extends from the coupling portion between cores into the coil channel and is arranged between the first and second coils in the axial direction.

2. The magnetically coupled reactor according to claim 1, wherein

the coupled core member includes

an outer leg configured as one of the two legs,

an inner leg configured as the other of the two legs,

a second coil channel formed by a second recess formed between the inner leg and a second outer leg on a side facing the first core and the second core, and

a second sheet-like magnetic body by which a second coupling portion between cores is put between the first core and the second core on a peripheral side at a second outer portion formed by the second outer leg,

the first coil and the second coil pass through the coil channel and the second coil channel, respectively, and are wound around the inner leg, and

the second sheet-like magnetic body includes a second portion arranged between coils that extends from the second coupling portion between cores into the second coil channel and is arranged between the first coil and the second coil in the axial direction.

3. The magnetically coupled reactor according to claim 1, wherein

the coupled core member includes

an outer leg configured as one of the two legs,

an inner leg configured as the other of the two legs,

a second coil channel formed by a second recess formed between the inner leg and the second outer leg on a side facing the first core and the second core, and

a second outer portion formed by the second outer leg, the sheet-like magnetic body includes

a second coupling portion between cores put between the first core and the second core at the second outer portion,

a second portion arranged between coils that extends from the second coupling portion between cores into the second coil channel and is arranged between the first coil and the second coil in the axial direction, and

an intermediate connecting portion arranged in a gap between the first core and the second core to couple the portion arranged between coils and the second portion arranged between coils, and

the first coil and the second coil are configured to pass through the coil channel and the second coil channel, respectively, and are wound around the inner leg.

4. The magnetically coupled reactor according to claim 1, wherein

the sheet-like magnetic body is arranged only at a portion overlapping the coupled core member when seen in the axial direction.

5. The magnetically coupled reactor according to claim 4, wherein

the sheet-like magnetic body blocks a portion between openings at both ends of the coil channel when seen in the axial direction.

6. The magnetically coupled reactor according to claim 5, wherein

the sheet-like magnetic body is arranged only at a portion between the openings at both ends of the coil channel when seen in the axial direction.

7. A power converter comprising:

a primary circuit; and

a secondary circuit magnetically coupled to the primary circuit via a voltage converter, wherein

the primary circuit or the secondary circuit includes

a first arm including two first switching elements connected in series with each other,

a second arm including two second switching elements connected in series with each other, and

a magnetically coupled reactor according to claim 1,

one end of the first coil is connected between the two first switching elements in the first arm,

one end of the second coil is connected between the two second switching elements in the second arm,

the other ends of the first coil and the second coil are connected to both ends of a voltage converting coil that constitutes the voltage converter on the primary circuit side, and

the power converter is used in a state where a negative-phase-sequence current flows through the first coil and the second coil.