CN112185669A - Framework for reactor, reactor and manufacturing method of reactor - Google Patents

Abstract

The invention provides a reactor bobbin in which a space in which a coil is arranged in a wound state is easily adjusted according to the size of the coil, a reactor using the reactor bobbin, and a method for manufacturing the reactor. The reactor bobbin (120) is configured to include: a frame body part (121) which is formed by extending a fixed flange part (121B) outward from one end part of a main body part (121A) in a hollow cylindrical shape; and an assembly flange section (122) which is assembled to the other end of the trunk section (121A) after the coil is arranged, and which enables the coil (110) to be arranged in a wound state around the trunk section (121A) between the fixed flange section (121B) and the assembly flange section (122).

Description

Framework for reactor, reactor and manufacturing method of reactor

Technical Field

The present invention relates to a reactor bobbin constituting a reactor used in circuits of various devices, a reactor using the reactor bobbin, and a method for manufacturing the reactor.

Background

The reactor is configured to include: a coil formed by winding a wire; a hollow tubular reactor bobbin which passes through the hollow core of the coil; and a magnetic core having legs inserted through the inner hollow portion of the reactor bobbin, the reactor bobbin being made of an insulating material to provide insulation between the coil and the magnetic core. As a bobbin for a reactor, a bobbin structure is proposed in which bobbin structural members are formed in a shape that divides a cylindrical body into two parts at a predetermined position in the axial direction of the cylindrical body, and the respective bobbin structural members are combined in a state of being inserted through a hollow portion of a coil wound body to form a cylindrical structure (for example, see patent documents 1 and 2).

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2011-198847

Patent document 2: japanese patent laid-open No. 2012-070001

However, in the case of the reactor bobbin described in the above patent document, in the assembling work, it is necessary to perform a work of connecting two bobbin structural members each having a flange portion at both ends in the hollow portion of the coil. In this case, the connecting portion is hardly visible from the outside of the coil, and thus, the operation is difficult. Further, since the flange portions are fixed to the respective skeleton structural members, the distance between the flange portions, in other words, the size of the space in which the coil is arranged in a wound state cannot be changed. Therefore, even if the length of the coil is within the range of the tolerance in design, there is a risk that: the distance between the flange portions is too small to dispose the coil, an excessive load is applied to the flange portions, or the distance between the flange portions is too large to cause the coil to shake. Further, when the length of the coil in design is changed by a change in specifications such as the number of turns, the reactor bobbin may need to be designed and manufactured again.

In particular, in an edgewise coil wound using a flat wire, since the winding is one layer, the length of the coil mounting portion of the reactor bobbin to which the edgewise coil is mounted in a wound state is made large in consideration of the thickness tolerance of the electric wire (example: ± 0.13mm × the number of windings). In this case, although the coil is fixed by filling varnish (varnish) or the like between the bobbin and the coil, when the difference between the length of the coil and the length of the coil mounting portion is large because the edgewise coil is hollow, the coil is fixed by vibration or the like, and various defects occur in terms of product and performance.

Disclosure of Invention

Problems to be solved by the invention

In view of the above circumstances, an object of the present invention is to provide a reactor bobbin in which a space in which a coil is assembled in a wound state can be adjusted according to a size of the coil while improving assembly of the coil, a reactor to which the reactor bobbin is applied, and a method for manufacturing the reactor.

Means for solving the problems

In order to solve the above problems, the reactor bobbin, the reactor, and the reactor manufacturing method according to the present invention have the following features.

First, a reactor bobbin according to claim 1 of the present invention is characterized by comprising: a trunk portion having a hollow cylindrical shape and in which the coil can be arranged in a wound state on an outer peripheral portion; and flange portions provided at both ends of the trunk portion, at least one of the flange portions provided at both ends being an assembly flange portion that can be assembled after the coil is disposed.

Next, a first group of the reactor bobbin according to the present invention includes: a trunk portion having a hollow cylindrical shape and in which the coil can be arranged in a wound state on an outer peripheral portion; and flange portions provided at both ends of the main portion, wherein the flange portion provided at one end is a fixed flange portion fixed to the main portion, and the flange portion provided at the other end is an assembly flange portion capable of being assembled after the coil is assembled to the main portion.

The above shows a preferred embodiment of the former for the reactor of the first group of the present invention.

The first reactor bobbin is characterized in that the fitting flange portion includes an engaging portion that engages with the trunk portion, the other end portion of the trunk portion includes an engaging receiving portion to which the engaging portion engages, and the engaging portion and the engaging receiving portion are engaged by selecting their engaging positions, whereby the gap between the fixed flange portion and the fitting flange portion can be adjusted.

More preferably, at least one of the engaging portion and the engaging receiving portion is formed in plural so as to be located at different positions from the fixed flange portion.

In this case, the engagement receiving portion may be provided on an outer peripheral surface of the trunk portion.

The reactor bobbin may include an engagement stopper portion capable of maintaining an engagement state between the engagement portion and the engagement receiving portion.

In the case where the reactor bobbin includes a pair of the trunk portions arranged in parallel, it is preferable that the fixed flange portion is provided at one end portion of each of the trunk portions, and the fitting flange portion is fitted to the other end portion of each of the trunk portions from the adjacent side.

In the case where a plurality of the trunk portions are arranged in parallel, at least one of the fixed flange portion fixed to one end portion of each trunk portion and the mounting flange portion mounted to the other end portion of each trunk portion may be integrated.

Next, a second group of the reactor bobbin according to the present invention includes: a trunk portion having a hollow cylindrical shape and in which the coil can be arranged in a wound state on an outer peripheral portion; and flange portions provided at both end portions of the trunk portion, the flange portions provided at both end portions being fitting flange portions capable of being fitted to the trunk portion.

The above shows a preferred embodiment of the bobbin for the reactor of the second group of the present invention.

Preferably, the fitting flange portion includes an engaging portion that engages with the trunk portion, and both end portions of the trunk portion include engaging receiving portions to which the engaging portions engage, respectively, and the fitting flange portion can be engaged with each other by selecting an engaging position between the engaging portion and the engaging receiving portion, so that an interval between the fitting flange portions can be adjusted.

More preferably, at least one of the engaging portion and the engaging receiving portion is formed in plural so as to be different in position in the axial direction of the trunk portion.

In this case, the engagement receiving portion may be provided on an outer peripheral surface of the trunk portion.

The reactor bobbin may include an engagement stopper portion capable of maintaining an engagement state between the engagement portion and the engagement receiving portion.

Preferably, the reactor bobbin includes a pair of the trunk portions arranged in parallel, and the fitting flange portion is fitted to at least one end portion of each of the trunk portions from an adjacent side.

In the case where the reactor bobbin includes a plurality of the trunk portions arranged in parallel, at least one of the mounting flange portion mounted to one end portion of each of the trunk portions and the mounting flange portion mounted to the other end portion of each of the trunk portions may be integrated.

In the reactor according to the present invention, the coil is disposed around the trunk portion of each of the reactor bobbins in a wound state, and the magnetic core is assembled so that the leg portion of the magnetic core is accommodated in the hollow portion of the trunk portion.

A first reactor manufacturing method according to the present invention is a reactor manufacturing method in which a coil is disposed in a wound state around a trunk portion of a reactor bobbin, and a magnetic core is assembled so that a leg portion of the magnetic core is housed in a hollow portion of the trunk portion, the reactor bobbin including flange portions at both end portions of the trunk portion in a hollow cylindrical shape, the reactor manufacturing method including: a skeleton forming step of forming a skeleton body portion having a fixed flange portion at one end portion of the trunk portion and an attachment flange portion attached to the other end portion of the trunk portion; a coil forming step of winding a wire to form a coil; a coil mounting step of passing the trunk through an air core of the coil to mount the coil around the trunk; a flange portion fitting step of fitting the fitting flange portion to a predetermined position of the other end portion of the trunk portion to which the coil is attached; and a core assembling step of assembling the magnetic core so that the leg portion of the magnetic core is accommodated in the hollow portion of the main portion provided with the coil and the fitting flange portion.

A second reactor manufacturing method according to the present invention is a reactor manufacturing method in which a coil is disposed in a wound state around a trunk portion of a reactor bobbin, and a magnetic core is assembled so that a leg portion of the magnetic core is housed in a hollow portion of the trunk portion, the reactor bobbin including flange portions at both end portions of the trunk portion in a hollow cylindrical shape, the reactor manufacturing method including: a skeleton forming step of forming the trunk portion and fitting flange portions which are the flange portions fitted to both end portions of the trunk portion; a coil forming step of winding a wire to form a coil; a first flange portion fitting step of fitting one of the fitting flange portions to a predetermined position at one end portion of the trunk portion; a coil mounting step of passing the trunk through an air core of the coil to mount the coil around the trunk; a second flange portion fitting step of fitting the other fitting flange portion to a predetermined position of the other end portion of the trunk portion to which the coil is fitted and the one fitting flange portion is fitted to the one end portion; and a core assembling step of assembling the magnetic core so that the leg portion of the magnetic core is accommodated in the hollow portion of the main portion provided with the coil and the fitting flange portion.

The "first flange portion assembling step", the "coil mounting step", and the "second flange portion assembling step" may be performed in this order, or the "second flange portion assembling step" may be performed after the order of the "first flange portion assembling step" and the "coil mounting step" is changed.

Effects of the invention

According to the present invention, there are provided a reactor bobbin and a reactor, including: a trunk portion having a hollow cylindrical shape and in which the coil can be arranged in a wound state on an outer peripheral portion; and flange portions provided at both ends of the trunk portion, at least one of the flange portions provided at both ends being an assembly flange portion to be assembled after the coil is disposed, whereby when the coil is disposed between the two flange portions, the assembly flange portion can be assembled to a predetermined position at the end of the trunk portion after the trunk portion of the bobbin body portion is inserted through the air core portion of the coil. Therefore, the flange portion can be mounted in a state that can be seen from the outside, and the assembling work can be easily and reliably performed.

Further, if the fitting flange portion includes an engaging portion that engages with the trunk portion, the other end portion of the trunk portion includes an engaging receiving portion that the engaging portion engages with, and the engaging portion and the engaging receiving portion are engaged by selecting their engagement positions, the gap between the two flange portions and the fitting flange portion can be adjusted, and the arrangement space of the coil can be adjusted according to the size of the coil. Therefore, it is possible to suppress a problem that the coil cannot be disposed due to a narrow distance between the flange portions or an excessive load is applied to the flange portions, and a problem that the coil rattles due to a wide distance between the flange portions. Therefore, the fitting flange portion can be suppressed from being unintentionally displaced or falling off.

Further, if at least one of the engaging portion and the engaging receiving portion is formed in plural so that the positions of the trunk portion in the axial direction are different from each other, the engaging position of the engaging portion and the engaging receiving portion can be easily selected, and the positioning of the fitting flange portion can be quickly performed.

Further, if the engagement receiving portion is provided on the outer peripheral surface of the trunk portion, the portion where the engagement portion of the fitting flange portion is engaged can be easily visually confirmed in the fitting operation of the fitting flange portion. Therefore, the assembling work can be easily performed without being stopped, and the work efficiency can be improved.

If the fitting flange further includes an engagement stopper portion capable of maintaining the engagement state between the engagement portion and the engagement receiving portion, the fitting flange can be further prevented from shifting or falling off.

Further, since the flange portion attached to at least one end portion of each trunk portion is restricted from moving in the lateral direction by the other trunk portion, the assembled flange portion can be prevented from coming off in the manufactured reactor.

Further, by providing a plurality of the trunk portions arranged in parallel and integrating at least one of the fitting flange portion fitted to one end portion of each trunk portion and the fitting flange portion fitted to the other end portion of each trunk portion, the number of components of the reactor bobbin can be reduced, and the flange fitting operation for the plurality of trunk portions can be performed at one time, thereby improving the manufacturing efficiency.

In addition, according to the reactor and the bobbin for a reactor of the second group of the present invention, the effects of the reactor and the bobbin for a reactor of the present invention can be obtained, and the mounting position of each mounting flange portion can be adjusted to a predetermined position according to the coil length, so that the relative position of the coil with respect to the trunk portion can be set to a desired state, and the degree of freedom in designing the reactor can be increased.

Further, by adjusting the mounting positions of the mounting flange portions at both ends to dispose the center position of the coil at a design setting position, desired magnetic characteristics can be secured.

In addition, a method of manufacturing a first reactor according to the present invention includes: a skeleton forming step of forming a skeleton body portion having a fixed flange portion at one end portion of the trunk portion, and an attachment flange portion attached to the other end portion; a coil forming step of winding a wire to form a coil; a coil mounting step of passing the trunk through an air core of the coil to mount the coil around the trunk; a flange portion mounting step of mounting the mounting flange portion to the main portion to which the coil is mounted; and a core assembling step of assembling the magnetic core so that the leg portion of the magnetic core is accommodated in the hollow portion of the main portion provided with the coil and the fitting flange portion, whereby the reactor can be assembled without hindrance using the bobbin for the reactor provided with the fitting flange portion and the coil, and the assembling work of the reactor can be facilitated.

On the other hand, a manufacturing method of a second reactor according to the present invention includes: a skeleton forming step of forming a trunk portion and fitting flange portions fitted to both end portions of the trunk portion; a coil forming step of winding a wire to form a coil; a first flange portion fitting step of fitting one of the fitting flange portions to a predetermined position at one end portion of the trunk portion; a coil mounting step of passing the trunk portion, to which the fitting flange portion is fitted at one end portion, through an air core portion of the coil to mount the coil around the trunk portion; a second flange portion fitting step of fitting the other fitting flange portion to a predetermined position of the other end portion of the trunk portion to which the coil is attached; and a core assembling step of assembling the magnetic core so that the leg portion of the magnetic core is accommodated in the hollow portion of the main portion provided with the coil and the fitting flange portion, whereby the reactor can be assembled without hindrance using the bobbin for the reactor provided with the fitting flange portion and the coil, and the assembling work of the reactor can be facilitated.

Drawings

Fig. 1 is a perspective view of a reactor including a reactor skeleton according to a first embodiment of the first group of the present invention.

Fig. 2 is an exploded perspective view of the reactor of fig. 1.

Fig. 3 is a perspective view of the reactor bobbin of fig. 1, where (a) is a state where the fitting flange portion is fitted to the bobbin body portion, and (b) is a state where the fitting flange portion is detached from the bobbin body portion.

Fig. 4 is an explanatory view of an assembly process of the reactor of fig. 1, (a) is an explanatory view of a coil mounting process, (b) is an explanatory view of a flange portion assembling process, and (c) is an explanatory view of a core assembling process.

Fig. 5 is an explanatory view of a reactor bobbin including a pair of trunk portions in a bobbin main body portion, according to a second embodiment of the first group of the present invention, (a) is a perspective view of a configuration in which an assembly flange portion is assembled to each trunk portion, and (b) is a perspective view of a configuration in which a single assembly flange portion is erected on the pair of trunk portions.

Fig. 6 is a perspective view of a reactor bobbin including three trunk portions in a bobbin main body portion according to a third embodiment of the first group of the present invention.

Fig. 7 is an explanatory view of a reactor bobbin including an engagement receiving portion formed of a groove having a V-shaped cross section and an engagement portion formed of a protrusion having a pointed cross section according to a fourth embodiment of the first group of the present invention, wherein (a) is a perspective view and (b) is a cross-sectional view in an engaged state of the engagement portion and the engagement receiving portion.

Fig. 8 is an explanatory view of a reactor bobbin including an engagement stopper portion including a concave portion and a convex portion according to a fifth embodiment of the first group of the present invention, where (a) is a perspective view and (b) is a cross-sectional view.

Fig. 9 is a perspective view of a reactor including the reactor bobbin according to the first embodiment of the second group of the present invention.

Fig. 10 is an exploded perspective view of the reactor of fig. 9.

Fig. 11 is a perspective view of the reactor bobbin of fig. 9, where (a) is a state where the fitting flange portion is fitted to the trunk portion, and (b) is a state where the fitting flange portion is detached from the trunk portion.

Fig. 12 is an explanatory view of an assembly process of the reactor of fig. 9, (a) is an explanatory view of a first flange portion assembly process, (b) is an explanatory view of a coil mounting process, (c) is an explanatory view of a second flange portion assembly process, and (d) is an explanatory view of a core assembly process.

Fig. 13 is an explanatory view of a reactor bobbin including a pair of trunk portions according to a second embodiment of the second group of the present invention, where (a) is a perspective view of a configuration in which a single fitting flange portion is provided between one end portions of the trunk portions and a separate fitting flange portion is provided at the other end portion, and (b) is a perspective view of a configuration in which a single fitting flange portion is provided between both end portions of the trunk portions.

Fig. 14 is a perspective view of a reactor bobbin provided with three trunk portions in parallel according to the third embodiment of the second group of the present invention.

FIG. 15 is an explanatory view of a reactor bobbin including an engagement receiving portion formed of a groove having a V-shaped cross section and an engagement portion formed of a protrusion having a pointed cross section according to a fourth embodiment of the second group of the present invention, (a) is a perspective view, and (b) is a cross-sectional view in a state where the engagement portion and the engagement receiving portion are engaged with each other

Fig. 16 is an explanatory view of one end portion of a reactor bobbin provided with an engagement stopper portion composed of a concave portion and a convex portion according to a fifth embodiment of the second group of the present invention, where (a) is a perspective view and (b) is a cross-sectional view.

Description of the reference numerals

100. 2100: a reactor; 110. 2110: a coil; 111. 2111: a hollow core portion; 120. 220, 320, 420, 520, 2120, 2220, 2320, 2420, 2520: a reactor skeleton; 121. 221, 321, 421, 521: a skeleton body portion; 121A, 221A, 321A, 421A, 521A, 2121, 2221, 2321, 2421, 2521: a trunk portion; 121B, 221B, 321B, 421B: a fixed flange portion; 121C, 221C, 321C, 421C, 521C, 2121C, 2221C, 2321C, 2421C, 2521C: clamping the bearing part; 122. 222, 223, 323, 422, 522, 2122, 2222, 2223, 2323, 2422, 2522: assembling the flange part; 1221. 3221: a first sheet; 1222. 3222: a second sheet; 1223. 3223: a third sheet; 122A, 223A, 323A, 422A, 2122A, 2223A, 2323A, 2422A: a fitting hollow portion; 122B, 223B, 323B, 2122B, 2223B, 2323B: a fitting inlet; 122C, 222C, 223C, 323C, 422C, 522C, 2122C, 2222C, 2223C, 2323C, 2422C, 2522C: a fastening part; 122D, 222D, 223D, 323D, 2122D, 2222D, 2223D, 2323D: clamping the limiting part; 130. 2130: a magnetic core; 131. 2131: a core block (core block); 132. 2132: a leg portion; 521E, 2521E: a recess; 522E, 2522E: a convex portion.

Detailed Description

< first group >

Hereinafter, a coil component of a reactor including a bobbin for a reactor according to a first embodiment of a first group of the present invention will be described with reference to fig. 1 to 4.

The reactor 100 is used as a circuit element of a solar power generation facility, a wind power generation facility, a charging facility for an electric vehicle, or the like, and is configured to include, as shown in fig. 1: a pair of coils 110 arranged in parallel; a pair of tubular reactor bobbins 120 to which the coils 110 are attached; and a ring-shaped magnetic core 130, a part of which passes through the hollow portion of each reactor bobbin 120. The reactor bobbin 120 is made of an insulator such as resin to insulate the coil 110 from the magnetic core 130. In the present specification, when the term "reactor frame" is used, if any one of the structural members is integrated, for example, when flange portions (fixed flange portions 121B and the like described below) formed at one ends of two main portions (121A and the like described below) are integrated with each other, the "reactor frame" is also expressed as one whole.

The coil 110 is an edgewise coil formed in a square tube shape by edgewise winding up one flat wire rod (electric wire), and has an air core portion 111 penetrating along the longitudinal direction (winding axis direction) of the coil 110 opened on the inner side, and the bobbin body portion 121 of the bobbin for reactor 120 can be inserted into the air core portion 111. The magnetic core 130 is configured in a ring shape by connecting the pair of U-shaped core blocks 131 in a symmetrical posture, and the leg portions 132 located at both end portions of the yoke portion of each core block 131 can be inserted into the body portion 121A of the frame 120 (see fig. 1 and 2).

Next, the reactor bobbin 120 will be explained.

As shown in fig. 3, the reactor bobbin 120 includes a bobbin body 121 and a mounting flange 122 mounted on the bobbin body 121. The bobbin body 121 includes a hollow rectangular tubular body portion 121A, and the coil 110 can be disposed around the body portion 121A in a wound state, and a fixed flange portion 121B extending outward over the entire circumference of the body portion 121A is provided at one end portion of the body portion 121A, and the fixed flange portion 121B is set in a state extending in a direction orthogonal to the axial direction of the body portion 121A. The hollow portion of the trunk portion 121A is inserted in the axial direction of the trunk portion 121A, and the leg portions 132 of the pair of core blocks 131 (magnetic cores 130) can be housed (inserted) into the hollow portion from both ends of the trunk portion 121A.

The fitting flange portion 122 is a thin-walled plate-shaped flange member that is fitted to the other end portion of the body portion 121A, has a substantially C-frame shape that is one turn larger than the rectangular cross section of the body portion 121A, and specifically, has a shape in which a second piece 1222 and a third piece 1223 vertically extend from the upper end and the lower end of a first piece 1221 that is long in the vertical direction in the drawing to the same lateral direction that is orthogonal to the first piece 1221. A fitting hollow portion 122A is opened in a central portion surrounded by the first, second, and third pieces 1221, 1222, and 1223, an open portion (between the tip of the second piece 1222 and the tip of the third piece 1223) in an outer peripheral portion formed by the continuous first to third pieces 1221 to 1223 is communicated with the fitting hollow portion 122A as a fitting inlet 122B, and the trunk portion 121A of the skeleton 120 is fitted into the fitting hollow portion 122A through the fitting inlet 122B (see fig. 3B). The opening edge portion of the fitting cavity 122A (the inner edge portion of the fitting flange portion 122 formed by the inner edges of the first to third pieces 1221 to 1223) is defined as an engagement portion 122C, and the engagement portion 122C is configured to be engaged with the main portion 121A side (specifically, the outer peripheral surface of the main portion 121A) when the main portion 121A is fitted to the fitting cavity 122A.

An engagement receiving portion 121C, with which the engagement portion 122C is engaged, is provided on the outer peripheral surface of the other end portion (the other end portion to which the fitting flange portion 122 is fitted) of the trunk portion 121A. Specifically, in a configuration in which the engagement receiving portion 121C formed of a groove having a rectangular cross section extends in the circumferential direction (direction orthogonal to the axial direction) of the trunk portion 121A, the engagement receiving portion 121C is set to be parallel to the fixed flange portion 121B. A plurality of (four in the present embodiment) engagement receiving portions 121C are formed so as to be arranged at equal intervals in a state shifted in the axial direction of the trunk portion 121A, and the distance between each engagement receiving portion 121C and the fixed flange portion 121B is different. In the present embodiment, the groove-shaped engagement receiving portion 121C is not formed in a part of the corner portion rounded at the outer peripheral surface of the other end portion of the trunk portion 121A, but the engagement receiving portion 121C may be formed continuously over the entire outer peripheral surface of the other end portion of the trunk portion 121A.

The reactor bobbin 120 includes an engagement stopper 122D capable of maintaining the engagement state between the engagement portion 122C and the engagement receiving portion 121C. As shown in fig. 3 (B), the engagement stopper portion 122D is configured by providing a pair of projections projecting toward the fitting inlet 122B side on both sides of the fitting inlet 122B, and is set to the same plate thickness dimension as the fitting flange portion 122, and further to the same plate thickness dimension as the engagement portion 122C (inner edge portion of the fitting flange portion 122).

In the embodiment shown in fig. 1 and 2 in which the pair of bobbins 120 are arranged side by side and adjacent to each other, the fixed flange portion 121B is fixedly disposed at one end of each of the trunk portions 121A, and the coil 100 is attached from the other end of the trunk portion 121A. Thereafter, the fitting flange portions 122 are respectively attached to the other end portions of the trunk portions 121A protruding from the coil 100, but the fitting direction is configured to be fitted from the adjacent side. That is, as shown in fig. 2, when the fitting flange portions 122 are attached to the two trunk portions 121A from the lateral direction, which is the opposite side, and are assembled with the leg portions 132 of the magnetic core 130, the fitting flange portions 122 are disposed so that the back portions of the first pieces 1221 in the longitudinal direction of the respective adjacent frames 120 approach each other (see fig. 1). Thus, in the manufactured reactor 100, the assembled fitting flange portion 122 cannot be detached.

Next, a method of manufacturing the reactor 100 will be explained.

In manufacturing the reactor 100, a process of forming each component of the reactor 100 and a process of assembling the reactor 100 using each component are performed. In the step of forming the components of the reactor 100, the bobbin body portion 121 and the mounting flange portion 122 are formed separately by injection molding or the like (a bobbin forming step), a flat wire material (electric wire) is wound up flatly to form the coil 110 (a coil forming step), and the U-shaped core block 131 is formed by performing powder compaction, cutting a metal block, stacking metal plates, or the like (a core block forming step).

After the respective components of the reactor 100 are formed, the assembly process of the reactor 100 is performed using the pair of bobbin body portions 121, the pair of fitting flange portions 122, the pair of coils 110, and the pair of core blocks 131. First, as shown in fig. 4 a, for each coil 110, the trunk portion 121A of the bobbin body portion 121 is inserted through the hollow portion 111 from the other end portion of the trunk portion 121A (the other end portion in a state where the mounting flange portion 122 is not mounted), and the coil 110 is mounted on the coil mounting portion, which is the periphery of the trunk portion 121A (coil mounting step). Then, one end of the coil 110 is brought into contact with the fixed flange 121B, and the other end of the stem 121A is projected from the other end of the coil 110 so that the engagement receiving portion 121C is exposed to the outside.

After the coil 110 is attached to the bobbin body 121, the flange portion 122 is attached to the other end portion (end portion including the engagement receiving portion 121C) of each of the stem portions 121A (flange portion attaching step). Specifically, as shown in fig. 4 (B), the fitting flange portion 122 is set in a posture in which the fitting inlet 122B faces the trunk portion 121A and is parallel to the fixed flange portion 121B with respect to the frame body portion 121, and the fitting flange portion 122 is bent to widen the fitting inlet 122B. Then, if the interval between the engagement stoppers 122D is widened to a state where the trunk portion 121A can be fitted, in this state, the fitting inlet 122B is brought close to the trunk portion 121A, and the fitting flange portion 122 is fitted to the other end portion of the trunk portion 121A. At this time, of the plurality of engagement receiving portions 121C, the engagement receiving portion 121C with which the engagement portion 122C can be engaged at a position where the fitting flange portion 122 abuts against the other end portion of the coil 110 or a position closest to the other end portion of the coil 110 is selected, and the engagement portion 122C is brought close to the selected engagement receiving portion 121C.

When the body portion 121A is disposed in the fitting hollow portion 122A so that the fitting flange portion 122 is sufficiently fitted to the body portion 121A, the engagement stopper portion 122D passes over the outer peripheral surface of the body portion 121A and is separated from the outer peripheral surface, so that the fitting flange portion 122 is released from the deflection, the engagement portion 122C engages with the engagement receiving portion 121C, and the engagement stopper portion 122D is hooked on the corner portion of the body portion 121A. As a result, the coil 110 is wound around each of the trunk portions 121A of the pair of reactor bobbins 120, and the engagement portions 122C and the engagement receiving portions 121C are engaged with each other by selecting the engagement positions, so that the distance between the fixed flange portion 121B and the mounting flange portion 122 is adjusted to match the actual size of the coil 110.

After the coil 110 is attached to the reactor bobbin 120, the leg portions 132 of the pair of magnetic cores 130 are inserted from both sides into the hollow portion of the body portion 121A and housed therein (core assembling step). Specifically, as shown in fig. 4 (c), the pair of reactor bobbins 120 to which the coil 110 is attached are arranged in a direction orthogonal to the axial direction of the trunk portion 121A, and one leg 132 of the U-shaped core block 131 is inserted into one end portion of the hollow portion of each trunk portion 121A, and the other leg 132 of the U-shaped core block 131 is inserted into the other end portion of the hollow portion of the trunk portion 121A. Then, if the distal ends of the leg portions 132 are joined to each other using an adhesive or the like in the hollow portion of the body portion 121A, the annular magnetic core 130 is formed, and a part of the magnetic core 130 is accommodated in the hollow portion of the body portion 121A (the reactor bobbin 120).

Then, a liquid insulating material such as varnish is applied to the surface of each coil 110, so that the insulating material is impregnated into the gap between the flat wires, or further filled between the coil (flat wire) 110 and the reactor bobbin 120 (the trunk portion 121A, the fixed flange portion 121B, and the fitting flange portion 122). Then, the insulating material is cured to perform an insulating treatment (surface treatment) of the coil 110, thereby completing the reactor 100. At this time, when the insulating material is cured, the coil 110 and the reactor bobbin 120 are fixed to each other with the insulating material interposed therebetween. The insulation treatment of the coil 110 may be performed between the flange assembly step and the core assembly step.

In this way, if the reactor bobbin 120 is configured by fitting the fitting flange portion 122 to the bobbin body portion 121 and the reactor bobbin 120 is used as a component of the reactor 100, the length of the space (the distance between the flange portions 121B and 122) in which the coil 110 is wound can be adjusted in accordance with the size of the coil 110. Therefore, it is possible to suppress a problem that the coil 110 cannot be disposed or the coil 110 cannot be biased to be disposed due to a narrow distance between the fixed flange portion 121B and the fitting flange portion 122 and an excessive load is applied to both flange portions 121B and 122, or a problem that the coil 110 can be reversely disposed but the distance between both flange portions 121B and 122 is wider than the coil length and rattling occurs. Even if the fixation of the coil 110 to the body portion 121A by an insulating material such as varnish is released by an external force such as vibration of the coil 110, the dimensional difference can be reduced, and the coil 110 can be prevented from largely wobbling by the flange portions 121B and 122.

Further, since the plurality of engagement receiving portions 121C are formed at different positions from the fixed flange portion 121B, and any one of the engagement receiving portions 121C is selected to engage the engagement portion 122C (in other words, the engagement portion 122C and the engagement receiving portion 121C are engaged by selecting their engagement positions), the distance between the fixed flange portion 121B and the fitting flange portion 122 can be adjusted, and therefore, unintentional displacement or falling-off of the fitting flange portion 122 can be suppressed. Further, the engagement position of the engagement portion 122C and the engagement receiving portion 121C can be easily selected, and the positioning of the fitting flange portion 122 can be quickly performed.

Further, since each engagement receiving portion 121C is provided on the outer peripheral surface of the body portion 121A, a portion where the engagement portion 122C of the fitting flange portion 122 is engaged can be easily visually confirmed in the fitting operation (flange portion fitting step) of the fitting flange portion 122. Therefore, the assembling work can be performed reliably without stopping, and the work efficiency can be improved. Further, since the engagement stopper portion 122D capable of maintaining the engagement state of the engagement portion 122C and the engagement receiving portion 121C is provided, the displacement and the falling-off of the fitting flange portion 122 can be further suppressed. Further, since reactor 100 is manufactured by a manufacturing method including the above-described steps (skeleton forming step, coil mounting step, flange portion assembling step, and core assembling step), reactor 100 can be assembled without hindrance using reactor skeleton 120 provided with assembled flange portion 122 and coil 110, and the assembling work of reactor 100 can be facilitated.

The reactor bobbin 120 in the first embodiment of the first group is configured to include the fixed flange portion 121B at one end of the trunk portion 121A of each of the pair of bobbin bodies 120 disposed adjacent to each other, but the present invention is not limited thereto. For example, the reactor former 220 of the second embodiment shown in fig. 5 is basically the same as the first embodiment of the first group, but differs in the following respects: the fixed flange portion 221B fixed to one end portion of the pair of trunk portions 221A provided in parallel to the frame body portion 221, or the fitting flange portion 223 fitted to the other end portion is integrally connected.

Specifically, the bobbin body portion 221 of the bobbin 220 for a reactor in the second embodiment of the first group shown in fig. 5 (a) and (B) includes a pair of trunk portions 221A arranged in parallel, and the fixed flange portion 221B arranged at one end portion of each trunk portion 221A is integrally and continuously formed, so that the one end portions of the pair of trunk portions 221A of the bobbin 220 are connected to each other by the fixed flange portion 221B. Further, the other end of each trunk portion 221A is provided with a plurality of engagement receiving portions 221C (four in the present embodiment) each formed of a groove, the plurality of engagement receiving portions 221C being arranged at equal intervals in the axial direction of the trunk portion 221A, and the distance between each engagement receiving portion 221C and the fixed flange portion 221B being set to be different for each engagement receiving portion 221C. In this aspect, the number of components can be reduced, and manufacturing efficiency can be improved.

In the embodiment shown in fig. 5 (a), a separate C-shaped fitting flange portion 222 is fitted to each trunk portion 221A from above in the drawing at the other end portion of each trunk portion 221A, and the engagement receiving portion 221C is engaged with the engagement portion 222C, so that the engagement state can be maintained by the engagement stopper portion 222D. Alternatively, in the embodiment shown in fig. 5 (b), the fitting flange portions 223 provided at the other end portions of the trunk portions 221A of the frame body portion 221 are also integrated. The integrated fitting flange portion 223 is configured by opening a pair of fitting empty portions 223A and a pair of fitting entrances 223B in a state of being arranged in a horizontal direction on a flat plate having a rectangular shape, and the fitting flange portion 223 is fitted between the other end portions of the trunk portion 221A in a bridged state, and the engagement receiving portion 221C is engaged with the engagement portion 223C, so that the engagement state can be maintained by the engagement stopper portion 223D.

If the separate fitting flange portion 222 is fitted to each of the trunk portions 221A of fig. 5 (a), even if the coils are designed to have different numbers of turns (winding numbers) from each other, or even have different length dimensions, the fitting portion of the fitting flange portion 222 can be adjusted to match the length dimensions of the respective coils. On the other hand, if the fitting flange portion 223 in fig. 5 (b) is mounted between the trunk portions 221A, the number of components of the reactor can be reduced. Further, the flange mounting work for the pair of trunk portions 221A can be performed at a time, and the manufacturing efficiency can be improved.

The third embodiment of the first group shown in fig. 6 shows a reactor bobbin 320 corresponding to three-phase alternating current, and is a configuration including three coils, as a whole, similarly to the configuration of fig. 5 (b). The bobbin body portion 321 of the bobbin 320 for a reactor of this embodiment is configured such that three trunk portions 321A are arranged in parallel (arranged in a direction orthogonal to the axial direction of each trunk portion 321A), and one end portion of each trunk portion 321A is connected by a fixed flange portion 321B formed integrally therewith.

In fig. 6, an integrated fitting flange portion 323 is attached to the other end portion of each trunk portion 321A, and the fitting flange portion 323 is formed in a flat plate shape in which three fitting recesses 323A and three fitting inlets 323B are opened in a lateral arrangement. The fitting flange portion 323 is fitted to each trunk portion 321A in a bridged state, and the engagement receiving portion 321C is engaged with the engagement portion 323C, and the engagement state can be maintained by the engagement stopper portion 323D. As in the embodiment of fig. 5 a, a separate mounting flange portion (not shown) may be attached to each trunk portion 321A.

In the first group of embodiments, the groove-shaped engagement receiving portions 121C, 221C, and 321C are formed on the four outer circumferential surfaces of the rectangular tubular trunk portions 121A, 221A, and 321A, but the present invention is not limited thereto. The range of the engagement receiving portion is not limited as long as the engagement portion can be engaged with the outer peripheral surface of the trunk portion. For example, a groove-shaped engagement receiving portion may be formed on the outer peripheral surface of the rectangular cylindrical trunk portion by selecting one or more of three surfaces that can face the inner edge portion (engagement portion) of the fitting flange portion, or a groove-shaped engagement receiving portion may be formed also on the corner portion of the outer peripheral surface of the trunk portion. In addition, the cylindrical trunk portion may be configured, and when the fitting flange portion is arc-shaped, the groove-shaped engagement receiving portion may be formed in a portion of the outer peripheral surface of the trunk portion that can face an inner edge portion (engagement portion) of the fitting flange portion, and it is not necessary to form the engagement receiving portion over the entire periphery of the outer peripheral surface of the trunk portion.

In the first group of embodiments, the engaging receiving portions 121C, 221C, and 321C are formed by grooves having a rectangular cross section, and the engaging portions 122C, 222C, 223C, and 323C have a rectangular cross section, but the present invention is not limited thereto. The key point is that the engagement portion and the engagement receiving portion are not limited as long as they can be engaged with each other.

For example, as shown in the fourth embodiment of the first group of fig. 7, in the reactor bobbin 420, the engagement receiving portion 421C may be formed as a groove having a V-shaped cross section and may be provided in the trunk portion 421A of the bobbin body portion 421, and the engagement portion 422C may be formed as a ridge having a pointed cross section and may be provided in the opening edge portion of the fitting hollow portion 422A of the fitting flange portion 422. If the engagement receiving portions 421C are formed by grooves having a V-shaped cross section, it is easier to set the pitch between the engagement receiving portions 421C to be narrow than in the case of grooves having a rectangular cross section, thereby improving the selectivity of the fitting position of the fitting flange portion 422 and the adjustability of the distance between the fixed flange portion 421B and the fitting flange portion 422.

In each of the embodiments of the first group, the plurality of engagement receiving portions 121C, 221C, and 321C provided in the trunk portions 121A, 221A, and 321A are each configured as a groove, and the engagement portions 122C, 222C, 223C, and 323C provided in the fitting flange portions 122, 222, 223, and 323 are each configured as a protrusion, but the present invention is not limited thereto. The key point is that any combination of the engaging portion and the engaging receiving portion may be adopted as long as the distance between the fixed flange portion and the fitting flange portion can be adjusted by selecting and engaging the engagement positions with each other. For example, the plurality of engagement receiving portions provided on the outer peripheral surface of the other end portion of the trunk portion may be formed by a protrusion or a pin-shaped protrusion, and the engagement portion provided on the opening edge portion of the fitting hollow portion of the flange portion may be formed by a groove.

In the first group of embodiments, the engagement receiving portions 121C, 221C, and 321C provided in the trunk portions 121A, 221A, and 321A are formed in plural numbers so as to be located at different positions (separated distances) from the fixed flange portions 121B, 221B, and 321B. The key point is that, as long as at least one of the engaging portion and the engaging receiving portion is formed in plural so as to be located at different positions from the fixed flange portion, the configuration is not limited. For example, the opening edge portion of the fitting hollow portion of the fitting flange portion may be expanded in the plate thickness direction of the fitting flange portion (the axial direction of the trunk portion), and a plurality of groove-like engaging receiving portions may be provided in the expanded edge portion so as to be shifted in the plate thickness direction of the fitting flange portion (the axial direction of the trunk portion). The engaging portion of the trunk portion for engaging with the engaging receiving portion is formed by a plurality of protruding strips, and the number of the protruding strips may be one or a plurality of protruding strips arranged in a staggered manner along the axial direction of the trunk portion so as to match the pitch of the plurality of engaging receiving portions. However, if the engagement portion on the main portion is formed of a projection, or the like and protrudes from the outer peripheral surface of the main portion, there is a risk that the engagement portion (the projection, or the like) is caught on the inner peripheral surface of the coil in the coil mounting process, and the assembly work is stopped. On the other hand, if the engaging portion on the trunk portion is configured not to protrude from the outer peripheral surface of the trunk portion (a groove, a recess, or the like configured by recessing the outer peripheral surface), the trunk portion is less likely to be caught by the inner peripheral surface of the coil in the coil mounting step, and the assembly work of the reactor is easily performed without stagnation, which is preferable.

In the first group of embodiments, the engagement stoppers 122D, 222D, 223D, and 323D having a protrusion structure are exemplified as the engagement stoppers of the present invention, but the present invention is not limited thereto. The key point is that any engagement limiting part may be used as long as the engagement state between the engagement part and the engagement receiving part can be maintained.

For example, as shown in the fifth embodiment of the first group in fig. 8, in the reactor bobbin 520, an engagement stopper portion may be formed by a concave portion 521E formed on the outer peripheral surface of the trunk portion 521A of the bobbin body portion 521 and a convex portion 522E provided so as to protrude from the fitting flange portion 522, and the engagement state between the engagement receiving portion 521C and the engagement portion 522C (the fitted state of the fitting flange portion 522) may be maintained by the engagement between the concave portion 521E and the convex portion 522E. Alternatively, a rectangular member (not shown) capable of closing the fitting entrance of the fitting flange portion may be used as the engagement stopper portion, and the fitting entrance of the fitting flange portion fitted to the body portion may be closed by the engagement stopper portion (rectangular member) to maintain the engagement state of the engagement portion and the engagement receiving portion, thereby preventing the fitting flange portion from coming off the body portion.

In the first group of embodiments, the fitting flange portions 122, 222, 223, 323 are formed of a single member having a substantially C shape or a substantially E shape, but the present invention is not limited thereto. The fitting flange portion may have any configuration as long as it can be fitted to the other end portion of the body portion. For example, two substantially C-shaped frame members may be opposed to each other to form a rectangular frame-shaped fitting flange portion, and in the flange portion fitting step, the main portion may be sandwiched between the two frame members, and in this state, the end portions of the frame members may be engaged with each other to fit the fitting flange portion to the main portion.

The coil 110 described in each of the embodiments of the first group is formed by winding a flat wire material in a flatly wound manner, but the present invention is not limited to this. The configuration is not limited as long as the coil is formed by winding a wire. For example, a coil formed by winding a round wire (a wire having a circular cross section) may be applied to the reactor and the reactor manufacturing method of the present invention.

< second group >

Hereinafter, a coil part including a bobbin for a reactor according to a first embodiment of a second group of the present invention will be described with reference to fig. 9 to 12.

The reactor 2100 is used as a circuit element of a solar power generation device, a wind power generation device, a charging device for an electric vehicle, or the like, and as shown in fig. 9, is configured to include: a pair of coils 2110 arranged in parallel; a pair of tubular reactor frames 2120 to which the coils 2110 are attached; and a ring-shaped magnetic core 2130, a part of which is inserted into the hollow portion of each reactor bobbin 2120. The reactor bobbin 2120 is made of an insulator such as resin to insulate the coil 2110 and the magnetic core 2130. In the present specification, when the term "reactor bobbin" is used, if any one of the structural members is integrated, for example, when flange portions (fitting flange portions 2122) formed at one ends of two main portions (e.g., 2121 described below) are integrated with each other, the "reactor bobbin" is also expressed as a single member as a whole.

The coil 2110 is an edgewise coil formed in a square tube shape by flatly winding up one flat wire rod (electric wire), and an air core portion 2111 penetrating along the longitudinal direction (winding axis direction) of the coil 2110 is opened inside thereof, and a trunk portion 2121 of a reactor bobbin 2120 can be inserted into the air core portion 2111. The magnetic core 2130 is configured in a ring shape by connecting a pair of U-shaped core blocks 2131 in a symmetrical posture, and the leg portions 2132 of each core block 2131 located at both end portions of the yoke portion can be inserted into the stem portion 2121 of the frame 2120 (see fig. 9 and 10).

Next, the reactor skeleton 2120 will be explained.

As shown in fig. 11, the reactor skeleton 2120 includes: a hollow rectangular tubular trunk portion 2121; and a pair of fitting flange portions 2122 fitted to both ends of the main portion 2121. The coil 2110 can be disposed around the body portion 2121 in a wound state, and can be inserted into the hollow portion of the body portion 2121 along the axial direction of the body portion 2121, and can be configured to be capable of housing (inserting) the leg portions 2132 of the pair of core blocks 2131 (magnetic cores 2130) into the hollow portion from both ends of the body portion 2121.

The mounting flange portion 2122 is a thin-walled plate-like flange member that is mounted on both end portions of the one end portion and the other end portion of the main portion 2121, and has a substantially C-frame shape that is one turn larger than the rectangular cross section of the main portion 2121, and specifically, has a shape in which the second piece 3222 and the third piece 3223 vertically extend from the upper end and the lower end of the first piece 3221 that is vertically long in the drawing in the same lateral direction that is orthogonal to the first piece 3221. A fitting hollow portion 2122A is opened in a central portion surrounded by the first, second, and third pieces 3221, 3222, and 3223, an open portion (between the distal end of the second piece 3222 and the distal end of the third piece 3223) in an outer peripheral portion formed by the continuous first to third pieces 3221 to 3223 is communicated with the fitting hollow portion 2122A as a fitting entrance 2122B, and a trunk portion 2121 of the skeleton 2120 is fitted into the fitting hollow portion 2122A through the fitting entrance 2122B (see fig. 11B). The opening edge of the fitting cavity 2122A (the inner edge of the fitting flange 2122 formed by the inner edges of the first to third pieces 3221 to 3223) is defined as an engaging portion 2122C, and the engaging portion 2122C is configured to engage with the main portion 2121 (specifically, the outer peripheral surface of the main portion 2121) when the main portion 2121 is fitted to the fitting cavity 2122A. In a state of being attached to the body portion 2121, the body portion is set in a posture extending in a direction orthogonal to the axial direction of the body portion 2121.

The outer peripheral surfaces of both end portions of the trunk portion 2121 (both end portions to which the fitting flange portions 2122 are fitted) are provided with engaging receiving portions 2121C to which the engaging portions 2122C are engaged, respectively. Specifically, the engagement receiving portions 2121C, which are formed of grooves having a rectangular cross section, extend in the circumferential direction (direction orthogonal to the axial direction) of the trunk portion 2121, and a plurality of (four in the present embodiment) engagement receiving portions 2121C are arranged in a state shifted at equal intervals in the axial direction of the trunk portion 2121. In the present embodiment, the groove-shaped engagement receiving portion 2121C is not formed in a part of the corner portion rounded at the outer peripheral surface of the trunk portion 2121, but the engagement receiving portion 2121C may be formed continuously over the entire periphery of the outer peripheral surface of the trunk portion 2121.

The reactor bobbin 2120 includes an engagement stopper portion 2122D capable of maintaining the engagement state between the engagement portion 2122C and the engagement receiving portion 2121C. As shown in fig. 11 (B), the engagement stopper portion 2122D is configured by providing a pair of projections projecting toward the fitting inlet 2122B side on both sides of the fitting inlet 2122B, and is set to have the same plate thickness as the fitting flange portion 2122, and further set to have the same plate thickness as the engaging portion 2122C (inner edge of the fitting flange portion 2122).

In the embodiment shown in fig. 9 and 10 in which the pair of bobbins 2120 are arranged side by side and adjacent to each other, first, the fitting flange portion 2122 is fitted to a predetermined position at one end of each of the body portions 2121, and the coil 2100 is fitted from the other end of each of the body portions 2121. Thereafter, the other fitting flange portion 2122 is attached to the other end portion of the trunk portion 2121 protruding from the coil 2100, but the fitting direction is configured to be fitted from the adjacent side. That is, as shown in fig. 10, when the other fitting flange portions 2122 are attached to both end portions of the two main portions 2121 in the lateral direction, which are opposite to each other, and then assembled to the leg portions 2132 of the magnetic core 2130, the fitting flange portions 2122 are attached to the adjacent frames 2120 such that the back portions of the first pieces 3221 in the longitudinal direction approach each other (see fig. 9). Thus, in the manufactured reactor 2100, the assembled fitting flange portion 2122 cannot be detached.

Next, a method for manufacturing the reactor 2100 will be described.

In manufacturing the reactor 2100, a step of forming each component of the reactor 2100 and a step of assembling the reactor 2100 using each component are performed. In the step of forming the components of the reactor 2100, the body portion 2121 and the fitting flange portion 2122 of the bobbin 2120 are formed separately by injection molding or the like (a bobbin forming step), the flat wire material (electric wire) is wound up in a flattened state to form the coil 2110 (a coil forming step), and the core block 2131 is formed by powder compacting, cutting a metal block, laminating metal plates, or the like (a core block forming step).

After the respective components of the reactor 2100 are formed, an assembly process of the reactor 2100 is performed using the pair of stem portions 2121, the pair of fitting flange portions 2122, the pair of coils 2110, and the pair of core blocks 2131. First, the fitting flange portion 2122 is fitted to one end of each of the main portions 2121 (first flange portion fitting step). Specifically, as shown in fig. 12 (a), the fitting flange portion 2122 is set in an extended posture in which the fitting inlet 2122B faces the stem portion 2121 and is orthogonal to the axial direction of the stem portion 2121 with respect to the stem portion 2121, and the fitting flange portion 2122 is bent to widen the fitting inlet 2122B. Then, if the interval between the engagement stoppers 2122D is widened to a state where the body portion 2121 can be fitted, the fitting entrance 2122B is brought close to the body portion 2121 in this state, and the fitting flange 2122 is fitted to one end of the body portion 2121. At this time, a predetermined engagement receiving portion 2121C for engaging the engagement portion 2122C of the fitting flange portion 2122 is selected from the plurality of engagement receiving portions 2121C at the one end portion of the trunk portion 2121 in advance based on the arrangement size of the coil 2110 such as the design and specification of the reactor 2100, and the engagement portion 2122C is brought close to the selected engagement receiving portion 2121C. When the main portion 2121 is disposed in the fitting hollow portion 2122A so that the fitting flange portion 2122 is sufficiently fitted to the main portion 2121, the engagement stopper portion 2122D passes over the outer peripheral surface of the main portion 2121 and is separated from the outer peripheral surface, so that the fitting flange portion 2122 is released from being deflected, the engagement portion 2122C is engaged with the engagement receiving portion 2121C, and the engagement stopper portion 2122D is hooked to a corner portion of the main portion 2121. As a result, the engagement portion 2122C and the engagement receiving portion 2121C select and engage with each other at their engagement positions, and the fitting flange portion 2122 is fitted to the one end portion of the main portion 2121.

Next, as shown in fig. 12 b, the stem portion 2121 of each coil 2110 is inserted through the air core portion 2111 from the other end portion of the stem portion 2121 (the other end portion in a state where the mounting flange portion 2122 is not mounted), and the coil 2110 is mounted on the coil mounting portion which is the periphery of the stem portion 2121 (coil mounting step). One end of the coil 2110 is brought into contact with a side surface of the assembled flange portion 2122 at one end of the body portion 2121, and the other end of the body portion 2121 is projected from the other end of the coil 2110 so that the engagement receiving portion 2121C is exposed to the outside. After the coil 2110 is attached, the fitting flange portion 2122 may be fitted to a predetermined position at one end of the body portion 2121.

After the coil 2110 is attached to the stem portion 2121, the remaining mounting flange portion 2122 is mounted to the other end portion (end portion including the engagement receiving portion 2121C) of each stem portion 2121 (second flange portion mounting step). Specifically, as shown in fig. 12 (c), the fitting flange portion 2122 before fitting is set to a posture in which the fitting inlet 2122B faces the main portion 2121 and is parallel to the fitting flange portion 2122 after fitting with respect to the main portion 2121, and the fitting flange portion 2122 before fitting is bent to widen the fitting inlet 2122B. Then, if the interval between the engagement stoppers 2122D is widened to a state where the body portion 2121 can be fitted, the fitting entrance 2122B is brought close to the body portion 2121 and the fitting flange 2122 is fitted to the other end of the body portion 2121 in this state. At this time, of the plurality of engagement receiving portions 2121C at the other end of the stem portion 2121, an engagement receiving portion 2121C is selected which can engage with the engagement portion 2122C at a position where the fitting flange portion 2122 before fitting abuts against the other end of the coil 2110 or a position closest to the other end of the coil 2110, and the engagement portion 2122C of the fitting flange portion 2122 before fitting is brought closer to the selected engagement receiving portion 2121C. When the main portion 2121 is disposed in the fitting hollow portion 2122A so that the fitting flange portion 2122 is sufficiently fitted to the main portion 2121, the engagement stopper portion 2122D passes over the outer peripheral surface of the main portion 2121 and is separated from the outer peripheral surface, so that the fitting flange portion 2122 is released from being deflected, the engagement portion 2122C is engaged with the engagement receiving portion 2121C, and the engagement stopper portion 2122D is hooked to a corner portion of the main portion 2121. As a result, the coil 2110 is wound around each of the stem portions 2121 of the pair of reactor bobbins 2120, and the engagement portions 2122C and the engagement receiving portions 2121C select the engagement positions to be engaged with each other, so that the distance between the fitting flange portions 2122 is adjusted to match the actual size of the coil 2110.

Next, the leg portions 2132 of the pair of magnetic cores 2130 are inserted into and accommodated in the hollow portion of the stem portion 2121 to which the coil 2110 is attached, from both sides (core assembling step). Specifically, as shown in fig. 12 (d), a pair of reactor bobbins 2120 to which coils 2110 are attached are arranged in a direction orthogonal to the axial direction of the stem portions 2121, and one leg portion 2132 of the U-core block 2131 is inserted into one end portion of the hollow portion of each stem portion 2121, and the other leg portion 2132 of the other U-core block 2131 is inserted into the other end portion of the hollow portion of the stem portion 2121. Then, if the tips of the leg portions 2132 are joined to each other by using an adhesive or the like in the hollow portion of the body portion 2121, the annular magnetic core 2130 is formed, and a part of the magnetic core 2130 is accommodated in the hollow portion of the body portion 2121 (the reactor frame 2120).

Then, a liquid insulating material such as varnish is applied to the surface of each coil 2110, so that the insulating material is impregnated into the gap between the flat wires, or is further filled between the coil 2110 (flat wire) and the reactor bobbin 2120 (the body portion 2121 and the fitting flange portion 2122). Then, the insulating material is cured to perform an insulating treatment (surface treatment) of the coil 2110, thereby completing the reactor 2100. At this time, when the insulating material is cured, the coil 2110 and the reactor bobbin 2120 are fixed by the insulating material. The insulation process of the coil 2110 may be performed between the second flange portion assembling step and the core assembling step.

Thus, if the reactor former 2120 is configured by attaching the attachment flange portion 2122 to the main portion 2121 and the reactor former 2120 is employed as a component of the reactor 2100, the length of the space in which the coil 2110 is wound (the distance between the attachment flange portions 2122) can be adjusted in accordance with the size of the coil 2110. Therefore, it is possible to suppress a problem that the coil 2110 or the biasing coil 2110 cannot be disposed due to a narrow distance between the fitting flange portions 2122 at both ends and an excessive load is applied to both the flange portions 2122, or a problem that the coil 2110 can be disposed but the distance between the fitting flange portions 2122 is wider than the coil length and rattling occurs. Even if the coil 2110 and the body portion 2121 are fastened by an insulating material such as varnish and the like and are released by an external force such as vibration of the coil 2110, the dimensional difference can be reduced, and thus the coil 2110 can be prevented from being largely shaken by the fitting flange portions 2122.

In addition, since the center position of the coil 2110 can be set at a design setting position by adjusting the mounting positions of the mounting flange portions 2122, the coil 2110 can be set in a state where the magnetic characteristics of the reactor are good.

Further, by adjusting the mounting position of each mounting flange portion 2122, the coil 2110 can be arranged in a state of being aligned with the center of the body portion 2121, and the relative position of the coil 2110 with respect to the body portion 2121 can be set to a desired design position, whereby the degree of freedom in designing the reactor 2100 can be increased. When the thickness of the coil 2110 wound around the reactor bobbin 2120 is changed due to a difference in specifications or the like, the fitting flange portions 2122 having an appropriate size (for example, a width capable of sufficiently covering the end portions of the coil 2110) may be separately manufactured for the thickness of the coil 2110 and fitted to both end portions of the body portion 2121. Therefore, the reactor bobbin 2120 can be realized in accordance with the shape change of the coil 2110.

Further, a plurality of engagement receiving portions 2121C are formed at one end portion and the other end portion of the trunk portion 2121 so as to be different in position in the axial direction of the trunk portion 2121, and by selecting any one of the engagement receiving portions 2121C to engage the engagement portion 2122C (in other words, by selecting and engaging the engagement position between the engagement portion 2122C and the engagement receiving portion 2121C), the interval between the fitting flange portions 2122 can be adjusted, and therefore, unintentional displacement or falling off of the fitting flange portion 2122 can be suppressed. Further, the engagement position between the engagement portion 2122C and the engagement receiving portion 2121C can be easily selected, and the fitting flange portion 2122 can be quickly positioned.

Further, since the engagement receiving portions 2121C are provided on the outer peripheral surface of the main portion 2121, the portions where the engagement portions 2122C of the fitting flange portion 2122 are engaged can be easily visually confirmed in the fitting operation (the first flange portion fitting step and the second flange portion fitting step) of the fitting flange portion 2122. Therefore, the assembling work can be easily and reliably performed without stagnation, and the work efficiency can be improved. Further, since the engagement stopper portion 2122D capable of maintaining the engagement state between the engagement portion 2122C and the engagement receiving portion 2121C is provided, the fitting flange portion 2122 can be further prevented from being displaced or detached. Further, since the reactor 2100 is manufactured by the manufacturing method including the above-described steps (the bobbin forming step, the coil forming step, the first flange portion mounting step, the coil mounting step, the second flange portion mounting step, and the core assembling step), the reactor 2100 can be assembled without hindrance by using the bobbin 2120 for a reactor provided with the mounting flange portion 2122 and the coil 2110, and the reactor 2100 can be manufactured without stagnation.

The reactor bobbin 2120 in the first embodiment of the second group is configured to have the separate fitting flange portions 2122 at both ends of the pair of barrel portions 2121 arranged adjacent to each other, but the present invention is not limited to this. For example, the reactor skeleton 2220 of the second embodiment of the second group shown in fig. 13 is basically the same as the first embodiment of the second group, but differs in the following respects: the fitting flange portions 2222 fitted to one end or both ends of the paired main portions 2221 are integrally connected to each other.

Specifically, the reactor bobbin 2220 in the second embodiment of the second group shown in fig. 13 (a) and (b) includes a pair of parallel trunk portions 2221, and engagement receiving portions 2221C each including a groove are provided at both ends of each trunk portion 2221, and a plurality of (four in the present embodiment) engagement receiving portions 2221C are arranged at equal intervals in the axial direction of the trunk portion 2221. The integrated fitting flange portion 2222 is configured such that a pair of fitting recesses 2222A and a pair of fitting inlets 2222B are formed in a rectangular flat plate in a horizontal arrangement, and the main portion 2221 is fitted to each fitting recess 2222A (in other words, the engagement receiving portion 2221C is engaged with the engagement portion 2222C), whereby one end portion or both end portions of each main portion 2221 are connected to each other by the fitting flange portion 2222. Further, the fitting inlet 2222B of the integrated fitting flange portion 2222 is provided with a protruding engagement stopper portion 2222D, so that the engagement state between the engagement receiving portion 2221C and the engagement portion 2222C can be maintained. In this aspect, the number of components can be reduced, and the flange mounting work for the pair of barrel portions 2221 can be performed at a time, thereby improving the manufacturing efficiency.

In the embodiment shown in fig. 13 (a), a separate C-shaped fitting flange portion 2223 is fitted to each of the main portions 2221 from above in the drawing at the other end portion of each of the main portions 2221, and the engagement receiving portion 2221C is engaged with the engagement portion 2223C, whereby the engagement state can be maintained by the engagement stopper portion 2223D. Alternatively, in the embodiment shown in fig. 13 (b), the integrated fitting flange portion 2222 is also fitted to the other end portion of each body portion 2221 in the same manner as described above.

If the separate fitting flange portion 2222 is fitted to each of the stem portions 2221 of fig. 13 (a), even if the coils are designed to have different numbers of turns (winding numbers) from each other, and even have different length dimensions, the fitting position of the fitting flange portion 2222 can be adjusted to match the length dimensions of the respective coils. On the other hand, if the integrally-fitted flange portion 2222 is also provided between the other end portions of the main portion 2221 in fig. 13 (b), the number of components of the reactor can be reduced. Further, the flange fitting work to the other end portions of the pair of main portions 2221 can be performed at one time, and manufacturing efficiency can be improved.

The third embodiment of the second group shown in fig. 14 shows a reactor skeleton 2320 corresponding to three-phase alternating current, and is a configuration including three coils, as a whole, similarly to the configuration of fig. 13 (b). The reactor skeleton 2320 of this embodiment includes three stem portions 2321, and the three stem portions 2321 are arranged in parallel (in a state of being arranged in a direction orthogonal to the axial direction of each stem portion 2321). Both ends of each trunk 2321 are connected by integrally-fitted flange portions 2323, 2323.

The integrally fitted flange portion 2323 is provided with three fitting recesses 2323A and three fitting inlets 2323B in a horizontally aligned state, is fitted to the end of each of the trunk portions 2321 in a bridged state, engages the engagement receiving portion 2321C with the engagement portion 2323C, and can maintain the engaged state by the engagement stopper portion 2323D. In this embodiment, as in fig. 13 (a), the integrated mounting flange 2323 may be mounted only on one of both ends of each of the body portions 2321 to connect the body portions 2321, and a separate mounting flange (not shown) may be mounted on the other end of each of the body portions 2321.

In the second group of embodiments, the groove-shaped engagement receiving portions 2121C, 2221C, and 2321C are formed on the four outer circumferential surfaces of the rectangular tubular stem portions 2121, 2221, and 2321, but the present invention is not limited to this. The range of the engagement receiving portion is not limited as long as the engagement portion can be engaged with the outer peripheral surface of the trunk portion. For example, a groove-shaped engagement receiving portion may be formed on the outer peripheral surface of the rectangular cylindrical trunk portion by selecting one or more of three surfaces that can face the inner edge portion (engagement portion) of the fitting flange portion, or a groove-shaped engagement receiving portion may be formed also on the corner portion of the outer peripheral surface of the trunk portion. In addition, the cylindrical trunk portion may be configured such that, when the fitting flange portion is formed in an arc shape corresponding to the fitting flange portion, a groove-shaped engagement receiving portion may be formed in a portion of the outer peripheral surface of the trunk portion that can face an inner edge portion (engagement portion) of the fitting flange portion, and it is not necessary to form the engagement receiving portion over the entire periphery of the outer peripheral surface of the trunk portion.

In the second group of embodiments, the engaging receivers 2121C, 2221C, and 2321C are formed by grooves having a rectangular cross section, and the engaging portions 2122C, 2222C, 2223C, and 2323C have a rectangular cross section, but the present invention is not limited thereto. The key point is that the engagement portion and the engagement receiving portion are not limited as long as they can be engaged with each other.

For example, as shown in the fourth embodiment of the second group in fig. 15, in the reactor bobbin 2420, the engagement receiving portion 2421C may be formed as a groove having a V-shaped cross section and be provided on the trunk portion 2421, and the engagement portion 2422C may be formed as a ridge having a pointed cross section and be provided on the opening edge portion of the fitting hollow portion 2422A of the fitting flange portion 2422. If the engagement receiving portions 2421C are formed of grooves having a V-shaped cross section, it is easier to set the pitch between the engagement receiving portions 2421C narrower than in the case of the grooves having a rectangular cross section, thereby improving the selectivity of the fitting position of the fitting flange portion 2422 and the adjustability of the distance between the fitting flange portions 2422 fitted to the respective end portions of the main portion 2421.

In the second group of embodiments, the plurality of engagement receiving portions 2121C, 2221C, 2321C provided in the stem portions 2121, 2221, 2321 are configured as grooves, and the engagement portions 2122C, 2222C, 2223C, 2323C provided in the fitting flange portions 2122, 2222, 2223, 2323 are configured as protrusions, respectively, but the present invention is not limited thereto. In the present invention, the engaging portion and the engaging receiving portion may be combined in any manner as long as the distance between the fitting flange portions can be adjusted by selecting the engaging positions and engaging the fitting flange portions. For example, the plurality of engagement receiving portions provided on the outer peripheral surface of the trunk portion may be formed by a protrusion or a pin-shaped protrusion, and the engagement portion provided on the opening edge portion of the fitting hollow portion of the fitting flange portion may be formed by a groove.

In the second group of embodiments, the engagement receivers 2121C, 2221C, 2321C provided in the stems 2121, 2221, 2321 are formed in plural numbers so that the positions of the stems 2121, 2221, 2321 in the axial direction are different from each other. The key point is that, as long as at least one of the engaging portion and the engaging receiving portion is formed in plural so as to make the positions of the trunk portion in the axial direction different, the configuration is not limited. For example, the opening edge portion of the fitting hollow portion of the fitting flange portion may be expanded in the plate thickness direction of the fitting flange portion (in other words, in the axial direction of the trunk portion), and a plurality of groove-like engagement receiving portions that are displaced in the plate thickness direction of the fitting flange portion (in the axial direction of the trunk portion) may be provided in the expanded edge portion. The engaging portion of the trunk portion for engaging with the engaging receiving portion is formed by a plurality of protruding strips, and the number of the protruding strips may be one or a plurality of protruding strips arranged in a staggered manner along the axial direction of the trunk portion so as to match the pitch of the plurality of engaging receiving portions. However, if the engagement portion on the main portion is formed of a projection, or the like and protrudes from the outer peripheral surface of the main portion, there is a risk that the engagement portion (the projection, or the like) is caught on the inner peripheral surface of the coil in the coil mounting process, and the assembly work is stopped. On the other hand, if the engaging portion on the trunk portion is configured not to protrude from the outer peripheral surface of the trunk portion (a groove, a recess, or the like configured by recessing the outer peripheral surface), the trunk portion is less likely to be caught by the inner peripheral surface of the coil in the coil mounting step, and the assembly work of the reactor is easily performed without stagnation, which is preferable.

In the second group of embodiments, the engagement stoppers 2122D, 2222D, 2223D, and 2323D having a protrusion structure are exemplified as the engagement stoppers according to the present invention, but the present invention is not limited to this. The key point is that any engagement limiting part may be used as long as the engagement state between the engagement part and the engagement receiving part can be maintained.

For example, as shown in the fifth embodiment of the second group in fig. 16, in the reactor bobbin 2520, the engagement stopper portion may be constituted by a concave portion 2521E formed on the outer peripheral surface of the trunk portion 2521 and a convex portion 2522E provided so as to protrude from the fitting flange portion 2522, and the engagement state between the engagement receiving portion 2521C and the engagement portion 2522C (the fitted state of the fitting flange portion 2522) may be maintained by the engagement between the concave portion 2521E and the convex portion 2522E. Alternatively, a rectangular member (not shown) capable of closing the fitting entrance of the fitting flange portion may be used as the engagement stopper portion, and the fitting entrance of the fitting flange portion fitted to the body portion may be closed by the engagement stopper portion (rectangular member) to maintain the engagement state of the engagement portion and the engagement receiving portion, thereby preventing the fitting flange portion from coming off the body portion.

Further, in each of the embodiments of the second group, the fitting flange portions 2122, 2222, 2223, 2323 are configured by a single member having a substantially C shape, a substantially E shape, or the like, for example, but the present invention is not limited thereto. The fitting flange portion may have any configuration as long as it can be fitted to the other end portion of the body portion. For example, two substantially C-shaped frame members may be opposed to each other to form a rectangular frame-shaped fitting flange portion, and in the flange portion fitting step, the main portion may be sandwiched between the two frame members, and in this state, the end portions of the frame members may be engaged with each other to fit the fitting flange portion to the main portion.

The coil 2110 described in each of the embodiments of the second group is formed by winding a flat wire material in a flat-wound manner, but the present invention is not limited thereto. The configuration is not limited as long as the coil is formed by winding an electric wire. For example, a coil formed by winding a round wire (a wire having a circular cross section) may be applied to the reactor and the reactor manufacturing method of the present invention.

Claims (18)

1. A bobbin for a reactor, comprising:

a trunk portion having a hollow cylindrical shape and in which the coil can be arranged in a wound state on an outer peripheral portion; and flange parts provided at both ends of the trunk part,

at least one of the flanges provided at both ends is an assembly flange that can be assembled after the coil is disposed.

2. A bobbin for a reactor, comprising:

a trunk portion having a hollow cylindrical shape and in which the coil can be arranged in a wound state on an outer peripheral portion; and flange parts provided at both ends of the trunk part,

among the flanges provided at both ends, the flange provided at one end is a fixed flange fixed to the trunk portion, and the flange provided at the other end is an attachment flange capable of being attached after the coil is attached to the trunk portion.

3. The former for a reactor according to claim 2,

the fitting flange portion includes an engaging portion that engages with the main portion side,

an engaging receiving portion for engaging with the engaging portion is provided at the other end of the trunk portion,

the engagement portion and the engagement receiving portion are engaged with each other by selecting an engagement position therebetween, so that a distance between the fixed flange portion and the fitting flange portion can be adjusted.

4. The former for a reactor according to claim 3,

at least one of the engaging portion and the engaging receiving portion is formed in plural so as to be located at different positions from the fixed flange portion.

5. The former for a reactor according to claim 3,

the clamping and receiving part is arranged on the outer peripheral surface of the main part.

6. The former for a reactor according to claim 3,

the reactor frame is provided with an engagement limiting portion capable of maintaining the engagement state of the engagement portion and the engagement receiving portion.

7. The former for a reactor according to claim 2,

the reactor bobbin includes a pair of the trunk portions arranged in parallel, the fixed flange portion is provided at one end portion of each of the trunk portions, and the fitting flange portion is fitted to the other end portion of each of the trunk portions from the adjacent side.

8. The former for a reactor according to claim 2,

the reactor bobbin includes a plurality of the trunk portions arranged in parallel, and at least one of the fixed flange portion fixed to one end portion of each of the trunk portions and the mounting flange portion mounted to the other end portion of each of the trunk portions is integrated.

9. A bobbin for a reactor, comprising:

a trunk portion having a hollow cylindrical shape and in which the coil can be arranged in a wound state on an outer peripheral portion; and flange parts provided at both ends of the trunk part,

the flange portions provided at both ends are fitting flange portions that can be fitted to the trunk portion.

10. The former for a reactor according to claim 9,

the fitting flange portion includes an engaging portion that engages with the main portion side,

the two end parts of the main trunk part are respectively provided with a clamping and receiving part for clamping the clamping part,

the distance between the fitting flange portions can be adjusted by selecting and engaging the engaging portions and the engaging receiving portions at their respective engagement positions.

11. The former for a reactor according to claim 10,

at least one of the engaging portion and the engaging receiving portion is formed in plural so that positions of the trunk portion in the axial direction are different from each other.

12. The former for a reactor according to claim 10,

the clamping and receiving part is arranged on the outer peripheral surface of the main part.

13. The former for a reactor according to claim 10,

the reactor frame is provided with an engagement limiting portion capable of maintaining the engagement state of the engagement portion and the engagement receiving portion.

14. The former for a reactor according to claim 9,

the reactor bobbin includes a pair of the trunk portions arranged in parallel, and the fitting flange portion fitted to at least one end portion of each of the trunk portions is attached from the adjacent side.

15. The former for a reactor according to claim 9,

the reactor bobbin includes a plurality of the trunk portions arranged in parallel, and at least one of the mounting flange portion mounted to one end portion of each of the trunk portions and the mounting flange portion mounted to the other end portion of each of the trunk portions is integrated.

16. A reactor is characterized in that a reactor body is provided,

the reactor is configured such that a coil is disposed around the trunk portion of the reactor bobbin according to claim 1 in a wound state, and the magnetic core is assembled so that the leg portion of the magnetic core is housed in the hollow portion of the trunk portion.

17. A method for manufacturing a reactor, wherein a coil is arranged around a trunk portion of a reactor bobbin in a wound state, and a magnetic core is assembled so that a leg portion of the magnetic core is housed in a hollow portion of the trunk portion, the reactor bobbin having flange portions at both end portions of the trunk portion in a hollow cylindrical shape,

the method for manufacturing a reactor is characterized by comprising:

a skeleton forming step of forming a skeleton body portion having a fixed flange portion at one end portion of the trunk portion and an attachment flange portion attached to the other end portion of the trunk portion;

a coil forming step of winding a wire to form a coil;

a coil mounting step of passing the trunk through an air core of the coil to mount the coil around the trunk;

a flange portion fitting step of fitting the fitting flange portion to a predetermined position of the other end portion of the trunk portion to which the coil is attached; and

a core assembling step of assembling the magnetic core so that the leg portion of the magnetic core is accommodated in the hollow portion of the main portion provided with the coil and the fitting flange portion.

18. A method for manufacturing a reactor, wherein a coil is arranged around a trunk portion of a reactor bobbin in a wound state, and a magnetic core is assembled so that a leg portion of the magnetic core is housed in a hollow portion of the trunk portion, the reactor bobbin having flange portions at both end portions of the trunk portion in a hollow cylindrical shape,

the method for manufacturing a reactor is characterized by comprising:

a skeleton forming step of forming the trunk portion and fitting flange portions which are the flange portions fitted to both end portions of the trunk portion;

a coil forming step of winding a wire to form a coil;

a first flange portion fitting step of fitting one of the fitting flange portions to a predetermined position at one end portion of the trunk portion;

a coil mounting step of passing the trunk through an air core of the coil to mount the coil around the trunk;

a second flange portion fitting step of fitting one of the fitting flange portions to a predetermined position of the other end portion of the trunk portion to which the coil is fitted and one of the fitting flange portions is fitted to the one end portion; and

a core assembling step of assembling the magnetic core so that the leg portion of the magnetic core is accommodated in the hollow portion of the main portion provided with the coil and the fitting flange portion.

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