JP2011198970A - Reactor and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor that can effectively reduce costs while maintaining its performance, and to provide its manufacturing method.SOLUTION: The reactor 1 has a cylindrical coil 2 that generates magnetic flux by applying current and a core 3, consisting of resin mixed with magnetic powder made by mixing magnetic powder into insulating resin and dispersing them, which is so disposed as to cover the periphery of the coil 2. The core 3 has a pair of core peripheral covering parts 32 for covering a pair of coil peripheral corners 22 formed between both axial directional edges (upper edge 201 and lower edge 202) of the coil 2 and the outer peripheral surface 204. On the pair of core peripheral covering parts 32, there is formed a peripheral curving part 321 that has a convex curving shape at a cross section including an axis line X of the coil 2.

Description

  The present invention relates to a reactor used in a power converter and the like and a method for manufacturing the reactor.

Conventionally, a reactor used for a power converter such as an inverter for a vehicle is known.
The reactor includes a cylindrical coil that generates a magnetic flux when energized, and a core disposed so as to cover the periphery of the coil. The core is made of a magnetic powder mixed resin obtained by mixing and dispersing magnetic powder such as iron powder in insulating resin such as epoxy resin. The coil and the core are stored in a storage case (see Patent Documents 1 and 2).

JP 2008-182152 A JP 2008-198981 A

  However, in the conventional reactor, since the molding die and the storage case have a shape that can be punched so as not to cause an undercut region in production, the magnetic flux generated by energizing the coil does not pass through, that is, as a magnetic circuit. A core was also formed in a portion that was hardly used (for example, around the corner on the outer peripheral side of the core). In particular, since the material constituting the core is expensive, extra material costs are incurred when the core is formed even in such a useless portion.

  The present invention has been made in view of such conventional problems, and an object of the present invention is to provide a reactor capable of effectively reducing costs while maintaining performance, and a method for manufacturing the same.

1st invention consists of the cylindrical coil which generate | occur | produces magnetic flux by electricity supply, and the magnetic powder mixed resin which mixed and disperse | distributed magnetic powder to the insulating resin, and was arrange | positioned so that the circumference | surroundings of the said coil might be covered A reactor comprising:
The core has a pair of core outer periphery covering portions that cover a pair of coil outer peripheral corner portions formed between the axial end faces and the outer peripheral surface of the coil,
The pair of core outer periphery covering portions has an outer peripheral curved surface portion having a convex curve shape in a cross section including the axis of the coil (Claim 1).

A second invention comprises a cylindrical coil that generates a magnetic flux when energized, and a magnetic powder mixed resin in which magnetic powder is mixed and dispersed in an insulating resin, and is disposed so as to cover the periphery of the coil A method of manufacturing a reactor comprising:
It has a box shape that is open upward and has a bottom and a cylindrical side that is erected from the outer periphery of the bottom, and an inner corner formed between the bottom and the side is the bottom and the side A coil placement step of placing the coil in a mold having a curved surface that is a concave curve in a vertical cross section perpendicular to the portion;
A curved surface member arranging step of arranging an annular curved surface member having a curved surface that is a concave curve in the vertical section on the outer peripheral portion of the opening of the mold, so that the curved surface faces inward,
After the coil placement step and the curved surface member placement step, a core forming step of forming the core by filling and curing the magnetic powder mixed resin in the mold in which the curved surface member is placed. (Claim 6) It exists in the manufacturing method of the reactor characterized by these.

  In the reactor of the first invention, the core has the pair of core outer periphery covering portions that cover the pair of coil outer peripheral corner portions. And the said outer periphery curved surface part is formed in this core outer periphery coating | coated part. That is, the magnetic flux generated by energization of the coil does not pass through, and the corner on the outer peripheral side of the core, which is hardly used as a magnetic circuit, is chamfered into a curved surface by the outer peripheral curved surface. . Therefore, the material used for the core can be reduced without affecting the magnetic characteristics. Thereby, cost can be effectively reduced while maintaining the performance.

  In the reactor manufacturing method according to the second aspect of the invention, a curved surface is formed at the inner corner of the molding die, and the curved member is disposed at the outer peripheral portion of the opening of the molding die. Then, the magnetic powder mixed resin is filled in the molding die in which the curved member is arranged, cured, and the core is formed, so that the magnetic flux generated by energization of the coil does not pass, and as a magnetic circuit The corners on the outer peripheral side of the core, which are hardly used, are chamfered in a curved shape. Therefore, the material used for the core can be reduced without affecting the magnetic characteristics. Thereby, the reactor which aimed at cost reduction effectively can be obtained, maintaining performance.

  Thus, according to the present invention, it is possible to provide a reactor capable of effectively reducing costs while maintaining performance, and a method for manufacturing the same.

Explanatory drawing which shows the whole reactor structure in Example 1. FIG. Explanatory drawing which looked at the reactor in Example 1 from upper direction. FIG. 3 is an explanatory view showing a molding die in Example 1. FIG. 3 is an explanatory view showing a state in which the core member is arranged in the molding die in Example 1. Explanatory drawing which shows the state which has arrange | positioned the coil in the shaping | molding die in Example 1. FIG. FIG. 3 is an explanatory diagram illustrating a state in which a curved surface member is arranged in a mold according to the first embodiment. Explanatory drawing which shows a mode that the magnetic powder mixed resin is filled in the shaping | molding die and a curved surface member in Example 1. FIG. Explanatory drawing which shows the reactor of the state which removed the curved-surface member from the core in Example 1. FIG. Explanatory drawing which shows the reactor of the state which removed the shaping | molding die and the curved surface member from the core in Example 2. FIG.

In the first invention, the reactor has a storage case for storing the coil and the core, and an inner peripheral surface of the storage case has a shape along the outer peripheral surface of the core. (Claim 2).
Here, when the coil is energized, the coil and the core generate heat and expand. And a thermal stress generate | occur | produces between the said core and the said storage case by the linear expansion coefficient difference, and the thermal stress concentrates on the corner | angular part of the outer peripheral side of the said core especially. However, since the outer peripheral curved surface portion is formed in the corner portion on the outer peripheral side of the core, the thermal stress can be relaxed in the outer peripheral curved surface portion. Thereby, the crack in the said core, peeling from the said storage case, etc. can be prevented.

Moreover, it is preferable that the convex curve of the outer peripheral curved surface portion is an arc having a radius of curvature of 1 mm or more.
In this case, while maintaining the performance, the effect of the present invention can be sufficiently achieved by effectively reducing the cost by reducing the material used for the core. Moreover, the effect of relieving thermal stress in the outer peripheral curved surface portion as described above can be sufficiently exhibited.
In addition, the convex curve of the outer peripheral curved surface portion reduces the number of the cores formed in a portion where a magnetic flux generated by energization of the coil does not pass (a portion that does not affect the magnetic properties), and affects the magnetic properties. It is preferable that the radius of curvature is 7 mm or less so as not to give it.

Further, the reactor has a columnar core member that is disposed in the axial direction on the inner peripheral side of the coil, and the core is between the axial end surfaces of the coil and the inner peripheral surface. A pair of core inner periphery covering portions covering the inner peripheral corner portions of the coil formed on the pair, and the pair of core inner periphery covering portions have a shape that forms a convex curve in a cross section including the axis of the coil. An inner circumferential curved surface portion is formed, and the inner circumferential curved surface portion can be formed along the outer circumferential surface of the core member.
In this case, the magnetic flux generated by energizing the coil does not pass, and the corner portion on the inner peripheral side of the core, which is a portion that is hardly used as a magnetic circuit, is chamfered into a curved shape by the inner peripheral curved surface portion. It is like that. Therefore, the material to be used can be reduced not only at the outer peripheral corner of the core but also at the inner peripheral corner. Thereby, cost reduction can be achieved more effectively while maintaining performance.

  When the coil is energized, the coil and the core generate heat and expand as described above. A thermal stress is generated between the core and the core member due to a difference in linear expansion coefficient, and the thermal stress is concentrated particularly on a corner portion on the inner peripheral side of the core. However, since the inner peripheral curved surface portion is formed at the corner portion on the inner peripheral side of the core, the thermal stress can be relaxed at the inner peripheral curved surface portion. Thereby, the crack in the said core, the peeling from the said core member, etc. can be prevented.

Further, by providing the core member, heat generated in the coil and the core can be transmitted to the core member and radiated. Thereby, heat dissipation can be improved.
In the case where the core member has the storage case, the core member can be fixed to the storage case with a bolt or the like. Moreover, it can also be set as the structure provided integrally in the said storage case. Alternatively, a part of the storage case may be integrally provided and the other part may be fixed with a bolt or the like.

Moreover, it is preferable that the convex curve of the inner peripheral curved surface portion is an arc having a curvature radius of 1 mm or more.
In this case, while maintaining the performance, the effect of the present invention can be sufficiently achieved by effectively reducing the cost by reducing the material used for the core. Moreover, the effect of relieving thermal stress in the inner peripheral curved surface portion as described above can be sufficiently exhibited.
Further, the convex curve of the inner peripheral curved surface portion reduces the core formed in a portion where a magnetic flux generated by energization of the coil does not pass (a portion that does not affect the magnetic property), and affects the magnetic property. It is preferable that the radius of curvature is set to 7 mm or less so as not to give the above.

In the second aspect of the invention, after the core forming step, it is preferable to use the molding die and the curved member as a storage case for housing the coil and the core without removing the molding die and the curved member. Item 7).
In this case, the production efficiency of the reactor can be increased by using the molding die for molding the core and the curved member as the storage case for finally storing the coil and the core. .

Moreover, it is preferable that the said curved surface member is removed from the said core after the said core formation process, and the said shaping | molding die is used as a storage case which accommodates the said coil and the said core (Claim 8).
In this case, since the removed curved member can be reused, the production cost can be reduced.

Moreover, it is preferable to remove the said shaping | molding die and the said curved surface member from the said core after the said core formation process (Claim 9).
In this case, the molding die and the curved member are used to mold the core, and the coil and the core from which the molding die and the curved member have been removed are connected to a case of a power converter such as an inverter. It can be stored in various storage cases depending on the final use.

  In addition, in the relationship between the core and the storage case, as described above, the effect of relaxing the thermal stress generated between the core and the storage case at the corner on the outer peripheral side of the core is obtained. Can do.

Moreover, it is preferable that the said concave curve of the said shaping | molding die and the said curved surface member is a circular arc whose curvature radius is 1 mm or more.
In this case, a curved surface can be reliably formed at the corner on the outer peripheral side of the core. Thereby, while maintaining the performance, the effect of the present invention of effectively reducing the cost by reducing the material used for the core can be sufficiently exhibited. Moreover, the effect of relieving thermal stress at the corners on the outer peripheral side of the core as described above can be sufficiently exhibited.
In addition, the concave curve of the mold and the curved member reduces the core formed in a portion where a magnetic flux generated by energization of the coil does not pass (a portion that does not affect the magnetic properties), and improves the magnetic properties. It is preferable to set the radius of curvature to 7 mm or less so as not to affect.

Moreover, before the said core formation process, the core member arrangement | positioning process which penetrates and arrange | positions a columnar core member in the axial direction in the inner peripheral side of the said coil is performed, and an axial direction is carried out at the both ends of the said core member The outer diameter increases as the end surface is approached, and a curved surface having a concave curve is formed in the vertical cross section (claim 11).
In this case, the magnetic flux generated by energizing the coil does not pass, and a curved surface can be formed at the corner on the inner peripheral side of the core, which is a part that is hardly used as a magnetic circuit. Therefore, the material to be used can be reduced not only at the outer peripheral corner of the core but also at the inner peripheral corner. Thereby, cost reduction can be achieved more effectively while maintaining performance.

Moreover, in the relationship between the core and the core member, as described above, the effect of relaxing the thermal stress generated between the core and the core member at the corner portion on the inner peripheral side of the core. Can be obtained.
In addition, as described above, the above-described effect of improving the heat dissipation property by the core member can be obtained.
The core member can be fixed to the bottom of the mold with a bolt or the like. Moreover, it can also be set as the structure integrally provided in the said shaping | molding die previously. Moreover, it can also be set as the structure which provides one part integrally in the said shaping | molding die previously, and fixes another part with a volt | bolt etc.

The concave curve of the core member is preferably an arc having a radius of curvature of 1 mm or more.
In this case, a curved surface can be reliably formed at the corner on the inner peripheral side of the core. Thereby, while maintaining the performance, the effect of the present invention of effectively reducing the cost by reducing the material used for the core can be sufficiently exhibited. Moreover, the effect of relieving thermal stress at the corners on the inner peripheral side of the core as described above can be sufficiently exhibited.
Further, the concave curve of the core member reduces the number of the cores formed in a portion where a magnetic flux generated by energization of the coil does not pass (a portion that does not affect the magnetic properties) and affects the magnetic properties. In order to prevent this, it is preferable that the radius of curvature is 7 mm or less.

  Moreover, as a material which comprises the said curved surface member, if this curved surface member is utilized as a part of said storage case, the aluminum etc. which are used as a material of this storage case are mentioned, for example. If the curved member is removed and reused, it is preferable to use a resin such as Teflon (registered trademark) so that the curved member can be easily removed.

Example 1
The reactor concerning the Example of this invention and its manufacturing method are demonstrated using figures.
As shown in FIGS. 1 and 2, the reactor 1 of this example includes a cylindrical coil 2 that generates a magnetic flux when energized, and a magnetic powder mixed resin in which magnetic powder is mixed and dispersed in an insulating resin. And a core 3 disposed so as to cover the periphery.
The core 3 has a pair of core outer periphery covering portions 32 that cover a pair of coil outer peripheral corner portions 22 formed between both axial end surfaces (upper end surface 201, lower end surface 202) of the coil 2 and the outer peripheral surface 204. The pair of core outer periphery covering portions 32 is formed with an outer peripheral curved surface portion 321 having a convex curve shape in a cross section including the axis X of the coil 2.
This will be described in detail below.

As shown in FIG. 1, the reactor 1 includes a cylindrical coil 2 and a core 3 made of a magnetic powder mixed resin disposed so as to cover the periphery of the coil 2.
The coil 2 is formed in a cylindrical shape by winding a copper wire in a spiral shape. In addition, a thermosetting resin such as an epoxy resin is used as the insulating resin that is a material constituting the core 3, and iron powder is used as the magnetic powder.

As shown in FIGS. 1 and 2, the coil 2 and the core 3 are housed in a bottomed cylindrical housing case 4 made of aluminum.
The storage case 4 has a bottom 51 and a cylindrical side surface 52 erected from the outer periphery of the bottom 51, and has a storage body 5 having a box shape opened upward, and an opening of the storage body 5. It is comprised by the annular | circular shaped curved surface member 6 arrange | positioned at the outer peripheral part 541 of the part 54. FIG.

As shown in FIG. 1, in the storage main body 5, a curved surface 531 that is a concave curve in the cross section including the axis X of the coil 2 is formed in the circumferential direction on the inner corner 53 formed between the bottom 51 and the side 52. Is formed.
The curved surface member 6 has a curved surface 601 that is a concave curve in a cross section including the axis X of the coil 2. The curved surface member 6 is disposed so that the curved surface 601 faces inward.

  As shown in FIGS. 1 and 2, an aluminum columnar core member 7 is disposed on the inner peripheral side of the coil 2 so as to penetrate the inner peripheral side of the coil 2 in the axial direction. The core member 7 is fixed to the bottom 51 of the storage body 5 of the storage case 4 with bolts or the like. Further, both end portions (upper end portion 71, lower end portion 72) of the core member 7 are formed with curved surfaces 711 and 721 that have an outer diameter that increases toward the end surface in the axial direction and that are concave curves in the vertical section. .

  As shown in FIG. 1, the core 3 includes a pair of core outer peripheries covering a pair of coil outer peripheral corners 22 formed between both axial end surfaces (upper end surface 201, lower end surface 202) of the coil 2 and the outer peripheral surface 204. A covering portion 32 is provided. In the pair of core outer periphery covering portions 32, an outer peripheral curved surface portion 321 having a shape that becomes a convex curve in a cross section including the axis X of the coil 2 is formed. The outer peripheral curved surface portion 321 is formed along the curved surface 531 of the inner corner portion 53 of the storage main body portion 5 and the curved surface 601 of the curved surface member 6. The convex curve of the outer peripheral curved surface portion 321 is an arc having a radius of curvature of 6 mm.

  As shown in the figure, the core 3 includes a pair of coil inner peripheral corner portions 21 that are formed between both axial end surfaces (upper end surface 201, lower end surface 202) of the coil 2 and the inner peripheral surface 203. A core inner periphery covering portion 31 is provided. In the pair of core inner peripheral covering portions 31, an inner peripheral curved surface portion 311 having a shape that becomes a convex curve in a cross section including the axis X of the coil 2 is formed. The inner circumferential curved surface portion 311 is formed along the outer circumferential surface 704 of the core member 7, specifically, curved surfaces 711 and 721 formed at both end portions (upper end portion 71 and lower end portion 72) of the core member 7. Yes. The convex curve of the inner peripheral curved surface portion 311 is an arc having a radius of curvature of 6 mm.

Next, the manufacturing method of the reactor 1 of this example is demonstrated.
When manufacturing the reactor 1 of this example, as shown in FIGS. 3-7, at least a coil arrangement | positioning process, a curved surface member arrangement | positioning process, and a core formation process are performed.

In the coil arrangement step, the box 51 is formed in an upwardly opened box shape having a bottom 51 and a cylindrical side surface 52 erected from the outer periphery of the bottom 51, and is formed between the bottom 51 and the side 52. The coil 2 is placed in a molding die 50 having a curved surface 531 in which the inner corner portion 53 is a concave curve in a vertical cross section perpendicular to the bottom portion 51 and the side surface portion 52.
In the curved surface member arranging step, the annular curved surface member 6 having the curved surface 601 having a concave curve in the vertical section is arranged on the outer peripheral portion 541 of the opening 54 of the mold 50 so that the curved surface 601 faces inward.
In the core forming step, after the coil arranging step and the curved surface member arranging step, the core 3 is formed by filling the magnetic powder mixed resin 30 in the mold 50 in which the curved surface member 6 is arranged and curing.
This will be described in detail below.

First, as shown in FIG. 3, a mold 50 is prepared. The mold 50 finally becomes the storage main body 5 (see FIG. 1) of the storage case 4.
Next, as shown in FIG. 4, the columnar core member 7 is placed at the center of the mold 50 (core placing step). The core member 7 is fixed to the bottom 51 of the mold 50 with a bolt or the like. The core member may be provided integrally with the mold 50 in advance. Further, a part may be provided integrally with the mold 50 and the other part may be fixed with a bolt or the like.

Next, as shown in FIG. 5, the coil 2 is placed in the mold 50 (coil placement step). At this time, the coil 2 is disposed so that the core member 7 is disposed through the inner peripheral side of the coil 2 in the axial direction. Further, a spacer or the like is disposed between the bottom 51 of the mold 50 and the coil 2, and the coil 2 is accurately disposed at a predetermined position.
Next, as shown in FIG. 6, the annular curved surface member 6 is disposed on the outer peripheral portion 541 of the opening 54 of the mold 50 (curved surface member arranging step). At this time, the curved surface member 6 is disposed so that the curved surface 601 faces inward. The curved surface member 6 finally becomes a part of the storage case 4 (see FIG. 1).

Next, as shown in FIG. 7, the magnetic powder mixed resin 30 is filled in the mold 50 to which the curved surface member 6 is attached, and the coil 2 is embedded in the magnetic powder mixed resin 30. And it heat-processes with respect to the magnetic powder mixed resin 30, the magnetic powder mixed resin 30 is hardened, and it is set as the core 3 (core formation process).
Thereby, the reactor 1 shown in FIG. 1 is obtained.

Next, the effect in the reactor 1 of this example and its manufacturing method is demonstrated.
In the reactor 1 of this example, the core 3 has a pair of core outer periphery covering portions 32 that cover the pair of coil outer peripheral corner portions 22. An outer peripheral curved surface portion 321 is formed on the core outer periphery covering portion 32. That is, the magnetic flux generated by energization of the coil 2 does not pass through, and the corner portion on the outer peripheral side of the core 3, which is a portion that is hardly used as a magnetic circuit, is chamfered into a curved shape by the outer peripheral curved surface portion 321. . Therefore, the material used for the core 3 can be reduced without affecting the magnetic characteristics. Thereby, cost can be effectively reduced while maintaining the performance.

  In this example, the reactor 1 has a storage case 4 (storage main body 5, curved surface member 6) that stores the coil 2 and the core 3, and the inner peripheral surface 403 of the storage case 4 is the outer peripheral surface of the core 3. It is a shape along 304. Here, when the coil 2 is energized, the coil 2 and the core 3 generate heat and expand. A thermal stress is generated between the core 3 and the storage case 4 due to the difference in linear expansion coefficient, and the thermal stress is concentrated particularly on the corner portion on the outer peripheral side of the core 3. However, since the outer peripheral curved surface portion 321 is formed at the corner portion on the outer peripheral side of the core 3, the thermal stress can be relaxed in the outer peripheral curved surface portion 321. Thereby, the crack in the core 3, the peeling from the storage case 4, etc. can be prevented.

  Further, the convex curve of the outer peripheral curved surface portion 321 is an arc having a radius of curvature of 1 mm or more. Therefore, while maintaining the performance, the effect of this example of effectively reducing the cost by reducing the material used for the core 3 can be sufficiently exhibited. Moreover, the effect of relieving thermal stress in the outer peripheral curved surface portion 321 as described above can be sufficiently exhibited.

  Further, the reactor 1 has a columnar core member 7 that is disposed so as to penetrate in the axial direction on the inner peripheral side of the coil 2, and the core 3 includes both axial end surfaces (upper end surface 201, lower surface) of the coil 2. A pair of core inner periphery covering portions 31 that cover a pair of coil inner peripheral corner portions 21 formed between the end surface 202) and the inner peripheral surface 203, and the pair of core inner periphery covering portions 31 includes the coil 2 An inner circumferential curved surface portion 311 having a shape that forms a convex curve in the cross section including the axis X is formed, and the inner circumferential curved surface portion 311 is formed along the outer circumferential surface 704 of the core member 7. That is, the magnetic flux generated by energization of the coil 2 does not pass through, and the corner portion on the inner peripheral side of the core 3, which is hardly used as a magnetic circuit, is chamfered into a curved shape by the inner peripheral curved surface portion 311. ing. Therefore, the material to be used can be reduced not only at the outer peripheral corner of the core 3 but also at the inner peripheral corner. Thereby, cost reduction can be achieved more effectively while maintaining performance.

  Further, when the coil 2 is energized, as described above, the coil 2 and the core 3 generate heat and expand. A thermal stress is generated between the core 3 and the core member 7 due to the difference in linear expansion coefficient, and the thermal stress is concentrated particularly on the corner portion on the inner peripheral side of the core 3. However, since the inner peripheral curved surface portion 311 is formed at the corner portion on the inner peripheral side of the core 3, the thermal stress can be relieved at the inner peripheral curved surface portion 311. Thereby, the crack in the core 3, peeling from the core member 7, etc. can be prevented.

  Further, the convex curve of the inner peripheral curved surface portion 311 is an arc having a radius of curvature of 1 mm or more. Therefore, while maintaining the performance, the effect of this example of effectively reducing the cost by reducing the material used for the core 3 can be sufficiently exhibited. Moreover, the effect of relieving thermal stress in the inner circumferential curved surface portion 311 as described above can be sufficiently exhibited.

  Further, in the manufacturing method of this example, after the core forming step, the molding die 50 (storage main body portion 5) and the curved surface member 6 are not removed, and the molding die 50 (storage main body portion 5) and the curved surface member 6 are connected to the coil 2 and the core. 3 is used as a storage case 4 for storing 3. That is, by using the forming die 50 and the curved surface member 6 for forming the core 3 as the storage case 4 for finally storing the coil 2 and the core 3, the production efficiency of the reactor 1 is improved and the production cost is reduced. Can do.

  Thus, according to this example, it is possible to provide the reactor 1 and the manufacturing method thereof that can effectively reduce the cost while maintaining the performance.

  In the manufacturing method of this example, as shown in FIG. 8, after the core forming step, the curved surface member 6 is removed from the core 3, and the molding die 50 (the storage main body 5) is stored in the storage case for storing the coil 2 and the core 3. 4 can also be used. In this case, since the removed curved surface member 6 can be reused, the production cost can be reduced. At this time, in order to easily remove the curved member 6 from the core 3, it is preferable that the curved member 6 is made of a resin such as Teflon (registered trademark).

(Example 2)
This example is an example in which the work after the core formation process is changed in the method for manufacturing a reactor.
In the manufacturing method of the reactor 1 of this example, as shown in FIG. 9, the mold 50 and the curved member 6 are removed from the core 3 after the core forming step.
Other configurations are the same as those in the first embodiment.

In the case of this example, the molding die 50 and the curved surface member 6 are used to mold the core 3, and the coil 2 and the core 3 from which the molding die 50 and the curved surface member 6 have been removed are used in a power conversion device such as an inverter. It can be stored in various storage cases according to the final use, such as a part of the case.
The other functions and effects are the same as those of the first embodiment.

DESCRIPTION OF SYMBOLS 1 Reactor 2 Coil 201 Upper end surface 202 Lower end surface 204 Outer peripheral surface 22 Coil outer peripheral corner part 3 Core 32 Core outer peripheral coating | coated part 321 Outer peripheral curved surface part X-axis

Claims (12)

A reactor comprising a cylindrical coil that generates magnetic flux when energized, and a core that is made of a magnetic powder mixed resin in which magnetic powder is mixed and dispersed in an insulating resin, and is disposed so as to cover the periphery of the coil. And
The core has a pair of core outer periphery covering portions that cover a pair of coil outer peripheral corner portions formed between the axial end faces and the outer peripheral surface of the coil,
The reactor is characterized in that an outer peripheral curved surface portion having a shape that forms a convex curve in a cross section including the axis of the coil is formed on the pair of core outer periphery covering portions.   The reactor according to claim 1, wherein the reactor has a storage case for storing the coil and the core, and an inner peripheral surface of the storage case has a shape along an outer peripheral surface of the core. Reactor.   3. The reactor according to claim 1, wherein the convex curve of the outer peripheral curved surface portion is an arc having a radius of curvature of 1 mm or more.   The reactor of any one of Claims 1-3 WHEREIN: This reactor has a column-shaped core member arrange | positioned and penetrated by the axial direction in the inner peripheral side of the said coil, The said core, The coil includes a pair of core inner periphery covering portions that cover a pair of coil inner peripheral corner portions formed between both axial end surfaces and the inner peripheral surface of the coil. An inner curved surface portion having a shape that forms a convex curve in a cross section including the axis of the coil is formed, and the inner circumferential curved surface portion is formed along the outer circumferential surface of the core member. .   5. The reactor according to claim 4, wherein the convex curve of the inner peripheral curved surface portion is an arc having a radius of curvature of 1 mm or more. Manufactures a reactor comprising a cylindrical coil that generates magnetic flux when energized, and a core that is made of a magnetic powder mixed resin in which magnetic powder is mixed and dispersed in an insulating resin, and is disposed so as to cover the periphery of the coil. A way to
It has a box shape that is open upward and has a bottom and a cylindrical side that is erected from the outer periphery of the bottom, and an inner corner formed between the bottom and the side is the bottom and the side A coil placement step of placing the coil in a mold having a curved surface that is a concave curve in a vertical cross section perpendicular to the portion;
A curved surface member arranging step of arranging an annular curved surface member having a curved surface that is a concave curve in the vertical section on the outer peripheral portion of the opening of the mold, so that the curved surface faces inward,
After the coil placement step and the curved surface member placement step, a core forming step of forming the core by filling and curing the magnetic powder mixed resin in the mold in which the curved surface member is placed. A method for manufacturing a reactor, characterized in that   7. The method for manufacturing a reactor according to claim 6, wherein, after the core forming step, the molding die and the curved member are not removed, and the molding die and the curved member are used as a storage case for housing the coil and the core. A reactor manufacturing method characterized by the above.   7. The reactor manufacturing method according to claim 6, wherein after the core formation step, the curved member is removed from the core, and the molding die is used as a storage case for storing the coil and the core. Manufacturing method.   The manufacturing method of the reactor of Claim 6 WHEREIN: The said shaping | molding die and the said curved surface member are removed from the said core after the said core formation process, The manufacturing method of the reactor characterized by the above-mentioned.   The method for manufacturing a reactor according to any one of claims 6 to 9, wherein the concave curve of the molding die and the curved member is an arc having a radius of curvature of 1 mm or more. .   The manufacturing method of the reactor of any one of Claims 6-10 WHEREIN: Before the said core formation process, the core member which penetrates and arrange | positions a columnar core member on the inner peripheral side of the said coil. A method of manufacturing a reactor, wherein an arrangement step is performed, and a curved surface having a concave curve in the vertical cross section is formed at both ends of the core member as the outer diameter thereof increases toward the end face in the axial direction. .   12. The method for manufacturing a reactor according to claim 11, wherein the concave curve of the core member is an arc having a radius of curvature of 1 mm or more.

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