JP2019165061A - Reactor manufacturing method - Google Patents

Abstract

To provide a reactor manufacturing method capable of avoiding entry of foreign matter such as iron powder generated by damage of a core into a coil during a manufacturing process of inserting the core into the coil.SOLUTION: The reactor manufacturing method includes steps of: performing coil molding a coil 2 wound so that a hollow portion 2a is formed with a resin R; and inserting a core 3 into the hollow portion 2a of the coil 2 molded by the coil molding. According to the manufacturing method, coil flat wires 2b are in close contact with each other with the coil molding so as to eliminate gaps, or even if there is a gap between the flat wires 2b, the gap is embedded in the resin R. Therefore, it is possible to eliminate an entry path of foreign matter such as iron powder of the core 3 to the coil 2 so as to avoid entry of foreign matter into the coil.SELECTED DRAWING: Figure 2C

Description

  The present invention relates to a reactor manufacturing method in which a core is inserted into a hollow portion of a coil.

  A method of manufacturing a reactor in which a core is inserted into a coil and then molded with a resin is known (Patent Document 1).

JP 2014-123680 A

  In this reactor, the core is assembled in a state where a gap can be generated between the windings of the coil. Therefore, for example, when the core is damaged in the manufacturing process of inserting the core into the coil, foreign matter such as iron powder generated by the damage of the core may enter the gap of the coil, damaging the enamel coating and shorting the coil. .

  Then, an object of this invention is to provide the manufacturing method of the reactor which can avoid the penetration | invasion of the foreign material to a coil.

  The method for manufacturing a reactor according to one aspect of the present invention includes a step of performing a coil molding in which a coil wound so that a hollow portion is formed is molded with a resin, and the coil molded with the coil mold. And inserting the core into the hollow portion.

The perspective view which showed the reactor which concerns on one form of this invention. The figure which showed the process of processing a coil. The figure which showed the process of performing coil molding. The figure which showed the process of inserting and fixing a core to the molded coil. The figure which showed the process of hardening the adhesive agent apply | coated to the core part. The figure which showed the process of molding the whole.

  A reactor 1 illustrated in FIG. 1 is provided in a vehicle such as an electric vehicle or a hybrid vehicle including an electric motor, and is applied to a converter that boosts a voltage of a battery and supplies the boosted voltage to the electric motor. The reactor 1 is molded with a molding resin S after assembling each component so as to be formed into a predetermined shape having a mounting flange 1a and the like.

  The reactor 1 includes a coil 2 and a core 3 assembled to the coil 2. As shown in FIG. 2A, the coil 2 is wound with an enamel-coated rectangular wire 2b, which is an example of a winding, so that a hollow portion 2a is formed. Therefore, a gap may be formed between the rectangular wires 2b with respect to the axial direction X of the coil 2, that is, the traveling direction of the spiral. The reactor 1 is manufactured through each process described below.

  As shown in FIG. 2A, the coil 2 in a state in which the flat wire 2b is wound so as to have the hollow portion 2a is processed into the illustrated shape, or the coil 2 that has been processed into the illustrated shape is prepared. Details of the processing method of the flat wire 2b are omitted.

  Next, as shown in FIG. 2B, the coil 2 shown in FIG. 2A is placed in a mold (not shown), and coil molding is performed in which the coil 2 is molded with a resin R so as to have a predetermined shape. FIG. 2B shows the coil in a coil-molded state. By performing this coil molding, the surface of the coil 2 including the inner peripheral surface of the hollow portion 2a of the coil 2 is covered with the resin R except for the terminal end portion 2c. In addition, the coil mold closes the rectangular wires 2b so that there is no gap, or even if there is a gap between the rectangular wires 2b, the gap is closed with the resin R. For this reason, it is possible to eliminate the entry path of foreign matter such as iron powder of the core 3 into the coil 2.

  Next, as shown in FIG. 2C, the core 3 is inserted into the hollow portion 2a of the coil 2 in a coil-molded state. The core 3 is made of a magnetic material and is divided into two core parts 3a and 3a formed in an approximately E shape. Each core part 3a, 3a is inserted into the hollow portion 2a of the coil 2 in a state where an adhesive is applied to these end faces, and these end faces are butted together and fixed (see also FIG. 2D). As a result, the core 3 passes through the hollow portion 2a of the coil 2 so as to surround the one side s1 and the other side s2 facing each other.

  Next, as shown in FIG. 2D, the adhesive is cured in a state where the core parts 3 a and 3 a of the core 3 are inserted and fixed in the hollow portion 2 a of the coil 2. In addition, as an adhesive used for adhesion of the core part 3a, for example, when an ultraviolet curable adhesive is used, ultraviolet rays are irradiated so that the adhesive is cured in the process of FIG. 2D.

  Next, as shown in FIG. 2E, the adhesive cured and the core 3 assembled to the coil 2 is placed in a mold (not shown) that gives a predetermined outer shape and molded with a resin S. Thereby, the reactor 1 is completed. The resin S may be the same as or different from the resin R used in the coil mold shown in FIG. 2B.

(Effect of this embodiment)
According to the manufacturing method described above, the coil flat wires 2a are in close contact with each other by the coil mold so that there is no gap, or even if there is a gap between the flat wires 2a, the gap is embedded in the resin R. Therefore, it is possible to eliminate the entry path of foreign matter such as iron powder of the core 3 into the coil 2. Accordingly, it is possible to avoid the entry of foreign matter into the coil. Since the coil 2 that is not coil-molded expands and contracts in a spring shape, for example, it may be difficult to hold it by carrying it to a subsequent process. According to the manufacturing method of this embodiment, since the coil 2 is maintained in a shape compressed and compressed by the coil mold, there is an advantage that handling in the manufacturing process becomes easy.

  Since the inner peripheral surface of the hollow portion 2a of the coil 2 is covered with the resin R and the coil 2 and the core 3 are insulated by the coil mold, an insulating component such as a bobbin is interposed between the coil 2 and the core 3, for example. There is no need to intervene and the number of parts can be reduced. Further, the position of the terminal portions 2c and 2c of the coil 2 is fixed by the coil mold, and the positional accuracy is improved. For example, when each of the end portions 2c and 2c is connected to the terminal on the vehicle side by welding when the reactor 1 is mounted on the vehicle, the end portions 2c and 2c for the connection are aligned with the terminal. Becomes easier.

(Modification)
Although the reactor 1 of the said form has a series of coils 2, the form which inserts a core by performing coil molding to a 2 series coil may be sufficient. The core 3 is divided into two E-shaped core parts 3a and 3a, but the number and shape of the cores are not limited. For example, the present invention can also be applied to a reactor manufacturing method in which a core divided into U-shaped core parts is inserted into two coils.

  Although the said form coil-molds the coil 2 independently, it is an example. For example, in the case of a reactor in which an intervening article such as a bobbin is provided between the core and the coil, a coil with a winding wound around the bobbin is prepared, and the coil and the bobbin are integrally coil-molded. It is also possible to implement.

  Aspects of the present invention derived from each of the above-described embodiments and modifications will be described below.

  The method for manufacturing a reactor according to one aspect of the present invention includes a step of performing coil molding in which a coil (2) wound so as to form a hollow portion (2a) is molded with resin (R) (FIG. 2B). And inserting the core into the hollow portion of the coil molded by the coil mold (FIG. 2C). In addition, although the reference code | symbol which concerns on the said form was written in parenthesis, it is not the meaning limited to the said form.

  According to the method for manufacturing a reactor of this aspect, the windings are brought into close contact with each other by the coil mold so that there is no gap, or even if there is a gap between the windings, the gap is closed with the resin. For this reason, it is possible to eliminate the entry path of foreign matter such as iron powder of the core into the coil. Accordingly, it is possible to avoid the entry of foreign matter into the coil. Moreover, since the coil is maintained in a shape compressed and contracted by the coil mold, there is an advantage that handling in the manufacturing process becomes easy.

1 Reactor 2 Coil 2a Hollow Part 3 Core R Resin

Claims (1)

A step of performing coil molding in which a coil wound so as to form a hollow portion is molded with resin;
Inserting the core into the hollow portion of the coil molded by the coil mold;
The manufacturing method of the reactor containing this.

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