JP2020092218A - Reactor and manufacturing method thereof - Google Patents

Abstract

To provide a reactor capable of reducing the effect of leakage flux in combined parts of annular magnetic cores composed of split cores, and manufacturing method thereof.SOLUTION: The reactor includes: An annular magnetic core constituted of split cores combined with each other; a core case that contains each of the split cores and is combined in an annular shape; and a vertically wound coil of flat wire wound on the core case. A vertically wound coil of flat wire has, between the one end and the other end of the coil, a narrower part where the spacing between adjacent rectangular conductors is smaller, and a wider part. The wider part is located in the combined part of the split cores. In the wider part, the flat conductor wire crosses the combination part diagonally only on the inner peripheral surface side of the annular magnetic core.SELECTED DRAWING: Figure 1

Description

The present invention relates to a reactor used for a converter circuit, a smoothing circuit, an active circuit of a hybrid vehicle, a fuel cell vehicle, an electric vehicle, and the like, and a manufacturing method thereof.

A hybrid vehicle or an electric vehicle, which is rapidly becoming popular in recent years, is provided with a high-output electric motor, and a reactor is used as a power conversion device used for driving the electric motor. As a general configuration, the reactor includes an annular magnetic core and a coil wound around the annular magnetic core, and has a high space factor formed by winding a rectangular conductor wire in a tubular shape in response to high voltage and large current. A rectangular conductor vertical winding coil (also called an edgewise coil) may be used.

In order to wind the flat conductor wire, it is necessary to apply a large deformation force, and it is difficult to wind it directly around the annular magnetic core. Therefore, as described in Patent Documents 1 to 3, the flat conductor wire is a cylindrical flat conductor wire vertical winding coil that extends linearly, and the annular magnetic core is composed of split cores, and the split core is formed from both ends of the flat conductor wire vertical winding coil. Are combined and coupled through. For example, in Patent Document 1, split cores are inserted into a rectangular conductor longitudinally wound coil, the divided cores are fastened together and assembled in an annular shape, and the winding interval of the rectangular conductor longitudinally wound coil is widened. As a result, a reactor is provided in which the rectangular conductor longitudinally-wound coil is arranged over substantially the entire circumference of the annular magnetic core.

JP, 2018-56511, A Chinese Patent Application Publication No. 10582598 Chinese Patent Application Publication No. 104269242

An annular magnetic core formed by combining split cores has a combination portion in the circumferential direction. The combined portion is a joint of magnetic paths, and is also a portion where the magnetic flux generated by the vertically-wound rectangular wire is difficult to pass. Therefore, leakage of magnetic flux is likely to occur around the periphery. Generally, the coil generates heat due to resistance loss, but the leakage magnetic flux also contributes to the heat generation of the coil. If a leakage magnetic flux enters the rectangular conductor around the combination, eddy current loss occurs and the coil heats up. Remarkable heat generation causes functional deterioration and heat damage of the reactor, so it is necessary to take heat countermeasures such as by separately providing a cooling means to enhance the cooling effect, which leads to an increase in size and cost of the reactor. In addition, there is a method to reduce the eddy current loss by separating the gap between the annular magnetic core and the coil so as to reduce the influence of the leakage magnetic flux, but in this case as well, the reactor is upsized, especially on the inner peripheral side of the annular magnetic core. Since the area is limited, it was difficult to provide the gap to the extent that it was not affected by the leakage magnetic flux.

Therefore, it is an object of the present invention to provide a reactor in which the influence of leakage magnetic flux in a combined portion of annular magnetic cores composed of split cores is reduced, and a manufacturing method thereof.

A first invention is a reactor including an annular magnetic core in which split cores are combined, a core case in which each of the split cores is included and is combined in an annular shape, and a rectangular conductor longitudinally wound coil wound around the core case. Wherein the rectangular wire longitudinally wound coil is provided with a narrow width portion and a wide width portion having a narrow spacing between adjacent flat wire conductors between one end and the other end of the coil, and the wide width portion is a combination of the split cores. The flat conductor wire is a reactor that is located in the wide portion and that extends over the combined portion only on the inner peripheral surface side of the annular magnetic core in the wide portion.

In the present invention, it is preferable that each of the split cores has a chamfered portion on an end face serving as the combination portion, and the chamfered portion is at least on an inner peripheral surface side of the annular magnetic core.

In the present invention, it is preferable that the number of times the rectangular conductor crosses the combination portion on the inner peripheral surface side of the annular magnetic core is one.

In the present invention, it is preferable that the rectangular conductor does not straddle any combination portion on both end sides of the rectangular conductor longitudinally wound coil.

In the present invention, it is preferable that the combination portion is located in a rotational symmetry of about 180 degrees with respect to the center of the annular magnetic core.

In the present invention, it is preferable that in the vertically-wound coil of the rectangular conductor wire, the interval between the adjacent rectangular conductor wires is widest in the middle portion of the coil.

In the present invention, it is preferable that each of the split cores is a powder magnetic core using flat powder of an Fe-based amorphous soft magnetic alloy, and is easily magnetized in the circumferential direction of the annular magnetic core.

A second aspect of the present invention comprises a step of preparing a rectangular conductor longitudinally-wound coil in which a rectangular conductor wire is longitudinally wound, a core case holding a split core is inserted from both ends of the rectangular conductor wire longitudinally wound coil, and combined, and the split core is formed into an annular shape. A step of forming a magnetic core and mounting the rectangular conductor longitudinally winding coil in the core case, and the split core so that the rectangular conductor extends over the combined portion of the split core only on the inner peripheral surface side of the annular magnetic core. At a position corresponding to the combination portion, the step of expanding the distance between the adjacent rectangular conductors of the rectangular conductor longitudinally wound coil in the circumferential direction of the annular magnetic core to deform it to form a wide portion, or of the rectangular conductor longitudinally wound coil in advance. And a step of arranging a wide portion obtained by widening and deforming an interval between the adjacent rectangular conductors to a combined portion of the split cores.

In the present invention, there is provided a method of manufacturing a reactor including a step of attaching a coil movement restricting member for restricting movement of a vertical conductor wire vertical winding coil to a core case that appears in a wide portion of the rectangular conductor wire vertical winding coil.

Further, in the present invention, the method for manufacturing a reactor also has a step of adhering the rectangular conductor wire and the core case at a wide portion of the rectangular conductor wire longitudinally wound coil.

ADVANTAGE OF THE INVENTION According to this invention, the reactor which reduced the influence of the leakage magnetic flux in the combination part of the split core which comprises an annular magnetic core, and its manufacturing method can be provided.

It is a front view of the reactor concerning one example of the present invention. It is a perspective view of the reactor concerning one example of the present invention. FIG. 6 is an exploded perspective view of the reactor excluding the terminal block, for explaining the method for manufacturing the reactor according to the embodiment of the present invention. It is a front view of a reactor before forming a wide part of a rectangular wire longitudinally winding coil. FIG. 6 is a front view of the reactor after the wide portion of the rectangular conductor wire vertical winding coil is formed. It is a figure for demonstrating the relationship between the combination part of a split core, and a rectangular conducting wire. It is a top view of the annular magnetic core used for the reactor concerning one example of the present invention. It is a perspective view of a split core used for a reactor concerning one example of the present invention. It is an exploded perspective view of a core case used for a reactor concerning one example of the present invention. FIG. 3 is a plan view of a core case that internally holds a split core in the reactor according to the embodiment of the present invention.

Hereinafter, the reactor according to the embodiment of the present invention will be specifically described. In some or all of the drawings, portions unnecessary for description are omitted, and there are portions illustrated in an enlarged or reduced form for ease of explanation. Further, the dimensions and shapes shown in the description, the relative positional relationship of the constituent members described with reference to the drawings, and the like are not limited to those descriptions, drawings, and the like unless otherwise specified. Further, in the description, the same name or reference numeral indicates the same or the same member, and the detailed description may be omitted even if it is illustrated.

1 is a front view of a reactor according to an embodiment of the present invention, and FIG. 2 is a perspective view thereof. 3 to 5 are views for explaining a method of manufacturing a reactor according to an embodiment of the present invention, and FIG. 3 is a step of inserting a core case holding a split core into a rectangular wire longitudinally wound coil. It is a figure for explaining. FIG. 4 is a front view showing a state in which the core case, through which the rectangular wire longitudinally-wound coil is passed, is assembled in an annular shape, and the rectangular wire longitudinally-wound coil is deployed over substantially the entire circumference. FIG. 5 is a plan view showing a state in which the spacing between the rectangular conductors is widened in the coil middle portion of the rectangular conductor longitudinally wound coil.

As shown in the figure, the reactor 1 of the present embodiment includes split cores (not shown) that form an annular magnetic core, a core case 20 that includes each of the split cores and can be assembled in an annular shape, and a core case that is assembled in an annular shape. 20 is provided with a rectangular conductor longitudinally-wound coil 30 wound around the outside. In the illustrated example, the reactor 1 is erected and adhesively fixed to the terminal block 50 on which the metal pins 52 for mounting the reactor 1 are erected so as to facilitate mounting on the circuit board. The end portion 32 side of the rectangular wire longitudinally-wound coil 30 passes through the through hole of the terminal block 50 and is drawn out to the lower side of the terminal block (the metal pin 52 side). Including such an aspect, the reactor of the present invention includes a case where other functional members are added to the basic configuration of the split core 5, the core case 20, and the rectangular wire longitudinally-wound coil 30.

The illustrated reactor 1 is provided with a wide portion 33 on the upper side in the z direction in which the distance between the rectangular conductors is widened in the middle portion (the middle portion between one end and the other end of the coil) of the rectangular conductor wire longitudinally wound coil 30. The end portion side of the rectangular wire longitudinally-wound coil 30 is pulled out to the lower side of the reactor 1. It should be noted that there is a narrow portion in which the distance between the rectangular conductors is narrow between one end of the coil and the wide portion and between the wide portion and the other end of the coil. The annular magnetic core in the core case 20 has a shape that conforms to the shape of the core case, and is configured by combining the end portions in the circumferential direction of a set of arc-shaped split cores. For example, in an annular magnetic core in which arcuate split cores having a central angle of about 180 degrees are combined, split core combination portions are provided at two locations that are rotationally symmetrical with respect to the center of the annular magnetic core by 180 degrees. The combined portion of the split cores (hereinafter, also simply referred to as “combined portion”) is linearly confirmed on the surface when the annular magnetic core is individually confirmed. As will be described later in detail, the annular magnetic core used in the illustrated reactor 1 also has a combination portion at two locations of rotational symmetry of 180 degrees, and the portion corresponding to one combination portion has a rectangular conductor longitudinally wound coil 30. The wide portion 33 is provided, and the spacing between the rectangular conductors in the coil middle portion is widest. The coil middle part is not limited to a mathematical middle part, but refers to a part including regions before and after the middle part.

The other combined portion of the split cores is on the terminal 52 side in FIG. 1 and is between the one end and the other end of the coil. There is a gap between one end and the other end of this coil. For this reason, there is no flat conductor wire that straddles the combined portion of the other split cores.

The combination part of the split cores is inside the core case, so it cannot be checked directly, but the combination part of the split cores and the combination part of the core case exist in the same place, so check the combination part of the core case. By doing so, the combined portion of the split cores can be confirmed. Alternatively, an opening may be provided in a part of the core case, and the combined portion of the split cores may be directly confirmed from there. In that case, after confirmation, it is desirable to close the opening with an insulating resin or the like to ensure insulation between the annular magnetic core and the rectangular conductor longitudinally wound coil.

The rectangular conductor wire longitudinally-wound coil 30 has a predetermined thickness and width, and is formed by winding a continuous single rectangular conductor wire, which is insulated and coated with enamel, with the same winding diameter and a predetermined number of turns. The cross-sectional size and the number of turns of the flat conductor wire are not limited and can be appropriately selected according to the application. The air-core portion of the flat wire longitudinally-wound coil 30 has a size and shape into which the core case 20 can be inserted, and is a rectangular space in the illustrated example. When the space between the rectangular conductor wires of the rectangular conductor vertical winding coil 30 is increased while being wound around the core case 20, the rectangular conductor longitudinal coil 30 can be deformed by the limitation due to the arcuate outer shape of the core case 20 and the radial thickness. This direction is substantially limited to the circumferential direction. Also, in the case of forming a wide portion in which the interval between the rectangular conductor wires is widened in advance, it is necessary to deform the rectangular conductor wire vertical winding coil 30 in consideration of the insertion of the core case 20. In either case, the area defined by the rectangular conductor that appears when the core case 20 is viewed in the y direction in the wide portion is a fan shape that decreases from the outer peripheral surface side to the inner peripheral surface side of the core case 20.

In the reactor 1 shown in the drawing, a flat conductor wire obliquely straddles the combination portion 8 on the inner peripheral surface side of the annular magnetic core 10. Here, when the flat conductor wire straddles the combination portion, as shown in FIG. 6, when the flat conductor wire 31 close to the inner peripheral surface of the core case 20 and the combination portion 8 of the split core 5 are overlapped with each other, the flat conductor wire is It means a state of intersecting with the combination portion 8 which is linearly confirmed on the surface of the annular magnetic core. According to the present invention, the rectangular conductor 31 can be configured to straddle the combination portion 8 only on the inner peripheral surface side of the annular magnetic core. By reducing the number of flat conductor wires that straddle the combined portion, it is possible to reduce the influence of the leakage magnetic flux in the combined portion. Preferably, the number of times the rectangular conductor crosses the combination portion 8 on the inner peripheral surface side of the annular magnetic core 10 is one.

The end portion side of the rectangular wire longitudinally-wound coil 30 is located in the vicinity of the lower combination portion. As shown in FIG. 1, it is preferable that the flat conductor wire on the end side of the flat conductor wire longitudinally wound coil 30 is drawn out at a position apart from the lower combined portion so that the combined portion cannot be straddled.

FIG. 7 shows a plan view of an annular magnetic core formed by combining divided cores, and FIG. 8 shows a perspective view of the divided core used for the annular magnetic core of FIG. 7. The end faces 6 in the circumferential direction of the split core 5 are made to face each other and combined to form an annular magnetic core 10. The split cores 5 shown have an arc shape with a central angle of about 180 degrees, but the split cores 5 are not limited to this, and may be different within a range that does not hinder the winding of the rectangular wire vertical winding coil 30 and the formation of the wide portion 33. I don't care. It may be U-shaped, which is a part of a straight-lined alphabet, and the annular magnetic core 10 that is a combination thereof has a flat elliptical shape. When the split cores 5 having the same shape are combined, the combination portion 8 is formed rotationally symmetrically with respect to the center of the annular magnetic core 10. The number of the split cores 5 forming the annular magnetic core 10 may be three or more, but the number of the combination parts 8 increases according to the number of combinations, and the winding intervals of the rectangular conductor vertical winding coils 30 are close. In this case, it is difficult to provide the wide portion 33 corresponding to the combination portion 8. Therefore, it is preferable that the number of combinations is 2. The annular core 10 may be configured by combining the split cores 5 having different central angles.

The end surface 6 of the split core 5 shown in the drawing is rounded into a curved surface (R chamfering) on the side that becomes the inner peripheral surface 11 and the outer peripheral surface 12 of the annular magnetic core 10. By forming a chamfer on the end surface 6 of the split core 5, the distance that the leakage magnetic flux leaks from the chamfered portion can be suppressed. On the inner peripheral surface side of the annular magnetic core 10, the leakage magnetic flux entering the rectangular conductor is reduced, and the generation of eddy current loss can be suppressed, and the coil heat generation can be prevented more effectively. Particularly, it is preferable to chamfer when a gap is provided in the combined portion 8 of the annular magnetic core 10. The chamfer may be, for example, a C chamfer such that the corner edge of the end face 6 is dropped to form a slope.

The split core 5 includes a ferrite core formed of Mn-based or Ni-based soft ferrite, pure iron, Fe-Si alloy, Fe-Cr alloy, Fe-Cr-Si alloy, Fe-Al alloy, Fe-Al. -Si alloy, Fe-Al-Cr alloy, Fe-Al-Cr-Si alloy, Fe-Ni alloy, Fe-MB alloy, etc. It is preferable to use a dust core. The powder of the soft magnetic alloy is an atomized powder obtained by an atomizing method such as water atomizing or gas atomizing, a flattened powder obtained by flattening it, or a flattened powder obtained by crushing an alloy cast in a strip shape. preferable. In the case of atomized powder, the average particle diameter (median diameter D50) is preferably 3 μm or more and 80 μm or less. The flat powder preferably has a thickness of 10 μm to 50 μm and a particle size in a direction perpendicular to the thickness direction of more than 2 times and not more than 6 times the thickness. The soft magnetic alloy powder may be a mixture of powders having different compositions or powders having different shapes (for example, atomized powder and flat powder), and may be made of a non-magnetic material such as Cu, Sn or Al so as to further improve the molding density. It may be a mixture of metal powder. Among them, it is preferable that the Fe-based amorphous soft magnetic alloy powder has a saturation magnetic flux density of more than 1.2T. Further, a flat powder obtained by crushing a thin strip is preferable because a powder magnetic core having shape anisotropy can be obtained.

The split core 5 that is a dust core using flat powder will be described. The pressure direction P indicated by the arrow in FIG. 8 indicates the pressure direction in compression molding. In general compression molding, a mold including a fixed mold and a movable mold is used. A pair of movable dies that close the opening of the fixed die are arranged above and below the fixed die, and the soft magnetic alloy powder is contained in the cavity defined by the opening of the fixed die and the lower movable die passed therethrough. The granulated powder in the cavity is compressed and the split cores 5 are molded by sliding the granulated powder in the cavity in a direction in which the upper and lower movable molds approach each other (P direction in FIG. 8). The granulated powder includes a soft magnetic alloy powder, an organic binder such as an acrylic resin or an epoxy resin, and an inorganic binder such as water glass. For example, a spray dryer or the like as a powder having an average particle diameter of 40 to 150 μm (median diameter D50). It is obtained by the spray dryer of. By using the granulated powder, the powder feeding property (flowability of powder) to the cavity at the time of molding is high, and the molding density of the split cores 5 can be increased. The molding pressure is typically 0. It can be molded at a pressure of 5 GPa or more and 2 GPa or less with a holding time of about several seconds. The pressure and the holding time are appropriately set depending on the content of the binder and the required strength of the molded body.

In the case of the arcuate split core 5, a C-shaped through hole of an alphabet with an R attached to each corner is formed in the fixed mold, and the movable mold corresponds to the C-shaped through hole. It is a C-shaped polygonal prism with R at each corner. According to such a configuration, it is easy to form a chamfer between the circumferential end surface 6 of the split core 5 and the inner peripheral surface 11 side and the outer peripheral surface 12 side. When chamfering is formed on the end surface 7 side of the split core 5 which is in the axial direction of the annular magnetic core 10, complicated multi-stage molding by changing the pressing direction or machining after molding is required. Since the rectangular conductor does not straddle the combination portion 8 on the end face 7 side, it is not easily affected by the leakage magnetic flux, and it is not necessary to actively form a chamfer unlike the inner peripheral face side.

The flat soft magnetic alloy powder tends to have its thickness direction aligned with the pressing direction P. By making the end surface 7 of the split core 5 a pressing surface by the movable mold, the split core 5 is easily magnetized in a plane orthogonal to the pressing direction P, and thus the annular magnetic core 10 is easily magnetized in the circumferential direction. It can have shape magnetic anisotropy.

FIG. 9 is an exploded perspective view of a core case used in a reactor according to an embodiment of the present invention, and FIG. 10 is a plan view showing a state in which a split core is housed in a first case member. The core case 20 is composed of two case members, a first case member 21 and a second case member 22. The first case member 21 in which the split cores are arranged has a C-shaped bottomed space 25, and has a form defined by an outer wall portion 26 and an inner wall portion 27 that integrally extend upward from the bottom portion. A receiving portion 23 having a stepped recess on the bottomed space 25 side is provided on one end side in the circumferential direction of the first case member 21, and a projecting piece having an outer circumferential side recessed on the other end side in the circumferential direction. The part 24 is formed. The second case member 22 closes the bottomed space 25 of the first case member 21 and is formed into a C-shaped plate. A receiving portion 28 whose upper side in the drawing is recessed stepwise is formed on one end side of the second case member 22, and a projecting piece 29 whose lower side is recessed stepwise is formed on the other end side. With such a configuration, the core cases 20 having the same shape can be used in an annular combination, so that the number of parts can be reduced and the manufacturing cost can be reduced.

The core case 20 is made of insulating resin. What is its material? Any resin having insulation properties, mechanical strength, chemical resistance, heat resistance, moisture resistance, and moldability may be used. PPS (Poly Phenylene Sulfide: polyphenylene sulfide) resin, liquid crystal polymer, PET (Polyethylene terephthalate) resin, PBT (Poly Butylene terephthalene) resin such as polybutylene terephthalate (Acrylonitrile terephthalate), ABS (ABS). It is possible to use those molded by a known method such as an injection molding method.

As shown in FIG. 10, the core case 20 that internally holds the split core 5 is formed by housing the split core 5 in the bottomed space of the first case member 21 and further closing it by the second case member 22. Both end sides of the core case 20 are open, and the end faces 6 of the split cores 5 appear from there. The end surface 6 of the split core 5 is located substantially evenly withdrawn from the circumferential end 23 of the core case 20.

Next, a method for manufacturing the reactor 1 will be described. As shown in FIG. 3, a pair of core cases 20 holding a straight-tube rectangular-shaped wire longitudinally wound coil 30 and a split core 5 using a rectangular-shaped wire are prepared, and a pair of core cases 20 are provided from both ends of the coil to the air core part. The core case 20 is inserted. Insert the core case 20 while deforming it so as to cover the rectangular wire longitudinally-wound coil 30 along the periphery of the core case 20, and insert the projecting piece at the end of the core case 20 into the receiving portion to fix the core case 20. Combine in a ring. In this state, as shown in FIG. 4, the rectangular conductor wire vertical winding coil 30 is wound around the outer circumference of the core case 20.

By performing the combination of the core case 20 with the projecting piece and the receiving portion, the combination position can be accurately determined, and the combination can be easily performed, and the combination of the split cores 5 is highly accurate with little variation. Can be done. The same core case 20 can be used even when an insulating spacer such as a resin film, ceramic or oil paper is inserted between the end faces of the pair of split cores 5 to form a magnetic gap. The insulating spacer may be bonded to the end surface of the split core 5 with an epoxy resin.

Silicone resin is injected as a filler into the core case 20, whereby the core case 20 and the split core 5 are temporarily fixed. The split cores 5 in the core case 20 are movable in the circumferential direction until the silicone resin is cured at room temperature. Therefore, even if the positions of the split cores 5 in the core case 20 are slightly displaced, when the core case 20 is assembled in an annular shape, the end faces of the split cores 5 are moved so as to come close to or contact with each other, and the cores 20 are accurately moved. Can be combined.

A wide portion 33 as shown in FIG. 5 is formed at a position corresponding to the combination portion 8 of the annular magnetic core 10 from a state in which the rectangular conducting wire vertical winding coil 30 is wound around substantially the entire outer circumference of the core case 20. The surface of the core case 20 is formed with a streak-shaped combination portion, which is formed as a result of the combination. As a guideline, the intervals between the adjacent rectangular conductors of the rectangular conductor vertical winding coil 30 are increased in the circumferential direction of the annular magnetic core 10. Transform it. The epoxy resin with which the core case 20 is filled is cured so that the split cores 5 are fixed in the core case 20, and the core cases 20 are fixed with an adhesive means such as an epoxy resin to form the reactor 1. With such a configuration, it is possible to form the reactor 1 in which the rectangular conductor extends over the combination portion 8 of the annular magnetic core 10 only on the inner peripheral surface side of the annular magnetic core 10.

Alternatively, the wide portion 33 may be formed in advance by widening and deforming the space between the adjacent rectangular conductors of the rectangular conductor longitudinally wound coil 30. In that case, the wide portion 33 may be positioned in the combined portion 8 of the annular magnetic core 10 with the combined portion of the core case 20 as a guide.

A coil movement restricting member such as a clip may be attached so that the coil does not move after the assembly and is not displaced in the wide portion 33. Alternatively, the flat conductor wire and the core case may be connected to each other in the wide portion of the flat conductor wire vertical winding coil. It may be fixed by adhesion.

The present invention is not limited to the contents of the above description, and can be appropriately modified within the scope of the same technical idea. According to the reactor of the present invention, it is possible to reduce the influence of the leakage magnetic flux in the combined portion of the annular magnetic cores including the split cores.

1 Reactor 5 Split core 10 Annular magnetic core 20 Core case 30 Flat wire vertical winding coil

Claims (10)

A reactor comprising an annular magnetic core in which split cores are combined, a core case that includes the split cores and is combined in an annular shape, and a rectangular conductor longitudinally wound coil wound around the core case,
The flat wire longitudinally wound coil includes, between one end and the other end of the coil, a narrow portion and a wide portion in which adjacent flat wire conductors have a narrow interval, and the wide portion is located in a combined portion of the split cores. ,
In the wide portion, the rectangular conductor extends over the combination portion only on the inner peripheral surface side of the annular magnetic core. The reactor according to claim 1, wherein
A reactor in which each of the split cores has a chamfered portion on an end surface serving as the combination portion, and the chamfered portion is at least on the inner peripheral surface side of the annular magnetic core. The reactor according to claim 1 or 2, wherein
A reactor in which the number of times that a rectangular conductor crosses the combined portion on the inner peripheral surface side of the annular magnetic core is 1. The reactor according to any one of claims 1 to 3,
The vertical conductor coil is a reactor in which the rectangular conductor does not straddle any combination part on both ends. The reactor according to any one of claims 1 to 4,
The combination portion is a reactor that is positioned in a rotational symmetry of about 180 degrees with respect to the center of the annular magnetic core. The reactor according to any one of claims 1 to 5,
A reactor in which the space between adjacent flat-shaped conductors is the widest in the middle of the coil. The reactor according to any one of claims 1 to 6,
A reactor in which each of the split cores is a dust core using flat powder of an Fe-based amorphous soft magnetic alloy, and is easily magnetized in the circumferential direction of the annular core. A step of preparing a flat wire vertical winding coil in which a flat wire is vertically wound;
Inserting and combining a core case that internally holds a split core from both ends of the flat conductor wire vertically wound coil, and forming an annular magnetic core with the split core, and mounting the flat conductor wire vertically wound coil on the core case,
An interval between adjacent rectangular conductors of the rectangular conductor vertical winding coil at a position corresponding to the combined portion of the split cores such that the rectangular conductors straddle the combined portion of the split cores only on the inner peripheral surface side of the annular magnetic core. A step of expanding and deforming the annular magnetic core in the circumferential direction to form a wide part, or a wide part obtained by expanding and deforming the interval between the adjacent rectangular conductors of the rectangular conductor longitudinally winding coil in advance in the combination part of the split cores. A method for manufacturing a reactor, including the step of positioning. The method for manufacturing the reactor according to claim 8, wherein
A method for manufacturing a reactor, comprising a step of mounting a coil movement restricting member for restricting movement of a rectangular conductor wire longitudinally wound coil on a core case appearing in a wide portion of the rectangular conductor wire longitudinally wound coil. The method for manufacturing the reactor according to claim 8, wherein
A method of manufacturing a reactor, comprising a step of adhering a rectangular conductor wire and a core case at a wide portion of the rectangular conductor wire vertical winding coil.

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