JP2020145380A

JP2020145380A - Reactor and manufacturing method of the same

Info

Publication number: JP2020145380A
Application number: JP2019042905A
Authority: JP
Inventors: 易央植草; Yasuhisa Uekusa; 浩太郎鈴木; Kotaro Suzuki
Original assignee: Tamura Corp
Current assignee: Tamura Corp
Priority date: 2019-03-08
Filing date: 2019-03-08
Publication date: 2020-09-10
Anticipated expiration: 2039-03-08
Also published as: JP2023168588A; JP7405510B2

Abstract

To provide a reactor capable of suppressing damage of a holding part and improving productivity, and provide a manufacturing method thereof.SOLUTION: A reactor comprises: a pair of coils 5a and 5b arranged in lateral with winding axes in parallel; a holding part 7 that is provided between the pair of coils, and holds a sensor 6 so as to surround it in an U-shape; and a resin body 30 (40) that covers a core member arranged on outside of the coil. The holding part 7 includes: a pair of opposite parts 71 and 72 that are formed so as to be continued with a part of the resin body coating the core member without a joint line, provided so as to be separated in a winding direction from an end face connected to the other core member of the core member, arranged so as to be opposite a direction parallel to the winding axis direction, and extended in one direction so as to be crossed to the winding axis direction; and a coupling part 73 that connects end parts of the pair of opposite parts. In at least one opposite part, a projection 74 projected toward the other opposite parts 71 and 72 is provided at the end part on the side opposite to the coupling part, and the opposite parts 71 and 72 and the coupling part 73 are solid.SELECTED DRAWING: Figure 3

Description

本発明は、センサを保持する保持部を備えたリアクトル及びその製造方法に関する。 The present invention relates to a reactor provided with a holding portion for holding a sensor and a method for manufacturing the reactor.

リアクトルは、ハイブリッド自動車や電気自動車の駆動システム等をはじめ、種々の用途で使用されている。例えば、車載用の昇圧回路に用いられるリアクトルとして、コアを被覆する樹脂体に一対のコイルを巻回したものが多く用いられる。 Reactors are used in a variety of applications, including drive systems for hybrid and electric vehicles. For example, as a reactor used in an in-vehicle booster circuit, a reactor in which a pair of coils are wound around a resin body covering a core is often used.

この種のリアクトルでは、コイルに高電流を流し続けるとコイルが過熱して、リアクトルとしての電気特性が低下するため、サーミスタなどの温度センサにより内部温度を検出して、コイルが一定温度以上に発熱しないように通電制御がなされる。 In this type of reactor, if a high current continues to flow through the coil, the coil overheats and the electrical characteristics of the reactor deteriorate. Therefore, the internal temperature is detected by a temperature sensor such as a thermistor, and the coil generates heat above a certain temperature. Energization control is performed so as not to prevent it.

特開２０１２−９４９２４号公報Japanese Unexamined Patent Publication No. 2012-94924

上記のように、リアクトルには、温度センサなど状態を検出するセンサが設けられるとともに、このセンサを保持する保持部が設けられている。この保持部は、コアを被覆する樹脂体と一体的に設けられていた。 As described above, the reactor is provided with a sensor for detecting a state such as a temperature sensor, and is provided with a holding portion for holding the sensor. This holding portion was provided integrally with the resin body covering the core.

図１０は、従来の樹脂体及び保持部の構成を示す図である。図１１は、従来の保持部の上面側から見た斜視図である。図１２は、従来の保持部の底面側から見た斜視図である。図１０に示すように、樹脂体１２０は、Ｈ字形状になるように組み合わせたコア部材を被覆し、二本の平行な長脚部１２１と、長脚部１２１の中央部分を繋ぐ連結部１２２とを有する。リアクトルを構成するコイルは、例えば、連結部１２２を境界とする４本の脚部１２３にそれぞれ嵌め込まれる。保持部１０７は、脚部１２３間に配置され、連結部１２２から脚部１２３の先端に向けて設けられている。但し、保持部１０７は、脚部１２３の先端までは突出していない。 FIG. 10 is a diagram showing the configuration of a conventional resin body and a holding portion. FIG. 11 is a perspective view seen from the upper surface side of the conventional holding portion. FIG. 12 is a perspective view seen from the bottom surface side of the conventional holding portion. As shown in FIG. 10, the resin body 120 covers the core members combined so as to form an H shape, and connects the two parallel long leg portions 121 and the central portion of the long leg portion 121. And have. The coils constituting the reactor are fitted into, for example, the four leg portions 123 having the connecting portion 122 as a boundary. The holding portion 107 is arranged between the leg portions 123, and is provided from the connecting portion 122 toward the tip of the leg portion 123. However, the holding portion 107 does not protrude to the tip of the leg portion 123.

図１１に示すように、保持部１０７は、一方向に延びる一対の対向部１７１、１７２と、対向部１７１、１７２の端部を繋ぐ連結部１７３とを有し、対向部１７２には、連結部１７３とは反対側の端部に、対向部１７１に向かって突出した突起１７４が設けられている。 As shown in FIG. 11, the holding portion 107 has a pair of facing portions 171 and 172 extending in one direction and a connecting portion 173 connecting the ends of the facing portions 171 and 172, and is connected to the facing portion 172. A protrusion 174 projecting toward the facing portion 171 is provided at the end opposite to the portion 173.

従来は、この樹脂体１２０及び保持部１０７を、二分割された金型で作製していた。そのため、対向部１７２に突起１７４を設けようとすると、突起１７４が連結部１７３との関係でアンダーカットとならないようにするために、対向部１７２及び連結部１７３の部分に、突起１７４を形成するための金型の凸部を入り込ませる必要がある。そのため、当該凸部が入り込んだ部分には樹脂が充填されないことから、図１１及び図１２に示すように、対向部１７２及び連結部１７３に空隙である中空部１７５が形成されて、対向部１７２及び連結部１７３が肉薄となる。そのため、センサを挿入する際に挿入口を広げるために対向部１７２を押し広げると、対向部１７２又は連結部１７３に負荷がかかり、これらの部分に破損が生じる場合があった。 Conventionally, the resin body 120 and the holding portion 107 have been manufactured by a mold divided into two parts. Therefore, when the protrusion 174 is to be provided on the facing portion 172, the protrusion 174 is formed on the facing portion 172 and the connecting portion 173 in order to prevent the protrusion 174 from being undercut in relation to the connecting portion 173. It is necessary to insert the convex part of the mold for the purpose. Therefore, since the resin is not filled in the portion where the convex portion has entered, as shown in FIGS. 11 and 12, a hollow portion 175 which is a gap is formed in the facing portion 172 and the connecting portion 173, and the facing portion 172 is formed. And the connecting portion 173 becomes thin. Therefore, when the facing portion 172 is expanded to widen the insertion opening when the sensor is inserted, a load is applied to the facing portion 172 or the connecting portion 173, and these portions may be damaged.

本発明は、上記のような課題を解決するためになされたものであり、その目的は、保持部の破損を抑制し、生産性を向上させることのできるリアクトル及びその製造方法を提供することにある。 The present invention has been made to solve the above problems, and an object of the present invention is to provide a reactor capable of suppressing damage to a holding portion and improving productivity, and a method for producing the same. is there.

本発明のリアクトルは、巻軸を平行にして横並びに配置された一対のコイルと、前記一対のコイルの間に設けられ、前記センサをＵ字状に取り囲んで保持する保持部と、前記コイルの外側に配置されるコア部材を被覆する樹脂体と、を備え、前記保持部は、前記コア部材を被覆する前記樹脂体の部分と継ぎ目なく一続きに形成され、前記コア部材の他のコア部材と接続される端面より前記巻軸方向に離れて設けられており、前記巻軸方向と平行な方向に対向して配置され、前記巻軸方向と交差するように一方向に延びる一対の対向部と、前記一対の対向部の端部を繋ぐ連結部と、を有し、少なくとも一方の前記対向部には、前記連結部とは反対側の端部に、他方の前記対向部に向かって突出する突起が設けられ、前記対向部及び前記連結部は、中実であること、を特徴とする。 The reactor of the present invention includes a pair of coils arranged side by side with their winding axes parallel to each other, a holding portion provided between the pair of coils and holding the sensor in a U shape, and the coil. A resin body for covering the core member arranged on the outside is provided, and the holding portion is seamlessly formed in succession with the portion of the resin body for covering the core member, and other core members of the core member. A pair of facing portions that are provided apart from the end face connected to the winding axis in the winding axis direction, are arranged to face each other in a direction parallel to the winding axis direction, and extend in one direction so as to intersect the winding axis direction. And a connecting portion connecting the ends of the pair of facing portions, and at least one of the facing portions protrudes toward the other facing portion at the end opposite to the connecting portion. It is characterized in that the facing portion and the connecting portion are solid.

本発明のリアクトルの製造方法は、巻軸を平行にして横並びに配置された一対のコイルと、前記一対のコイルの間に設けられ、前記センサをＵ字状に取り囲んで保持する保持部と、前記コイルの外側に配置されるコア部材を被覆する樹脂体と、有するリアクトルの製造方法であって、前記保持部は、前記コア部材の他のコア部材と接続される端面より前記巻軸方向に離れて設けられ、前記巻軸方向と平行な方向に対向して配置され、前記巻軸方向と交差するように一方向に延びる一対の対向部と、前記一対の対向部の端部を繋ぐ連結部と、を有し、前記巻軸の方向及び前記横並びの方向に直交する上下に分割された上型及び下型内に前記コア部材をセットし、樹脂を充填して前記樹脂体を成型する樹脂体成型工程と、前記樹脂体成型工程の際に、前記樹脂体の一部として、前記保持部を、前記横並びの方向である左右に分割された左型及び右型により成型する保持部成型工程と、を備えること、を特徴とする。 The method for manufacturing a reactor of the present invention includes a pair of coils arranged side by side with their winding axes parallel to each other, a holding portion provided between the pair of coils and holding the sensor in a U shape. A method of manufacturing a reactor having a resin body covering a core member arranged outside the coil, wherein the holding portion is in the winding axis direction from an end surface connected to another core member of the core member. A pair of facing portions that are provided apart from each other, are arranged so as to face each other in a direction parallel to the winding axis direction, and extend in one direction so as to intersect the winding axis direction, and a connection that connects the ends of the pair of facing portions. The core member is set in the upper and lower molds which have a portion and are orthogonal to the direction of the winding axis and the direction of the side-by-side arrangement, and is filled with resin to mold the resin body. During the resin body molding step and the resin body molding step, the holding portion is molded as a part of the resin body by the left and right molds divided into left and right in the side-by-side direction. It is characterized by having a process.

本発明によれば、保持部の破損を抑制し、生産性を向上させることのできるリアクトル及びその製造方法を得ることができる。 According to the present invention, it is possible to obtain a reactor and a method for producing the same, which can suppress damage to the holding portion and improve productivity.

実施形態に係るリアクトルの斜視図である。It is a perspective view of the reactor which concerns on embodiment. 実施形態に係るリアクトルの分解斜視図である。It is an exploded perspective view of the reactor which concerns on embodiment. 保持部の構成を示す図であり、樹脂体の側面図である。It is a figure which shows the structure of the holding part, and is the side view of the resin body. 保持部の構成を示す図であり、樹脂体の平面図である。It is a figure which shows the structure of the holding part, and is the top view of the resin body. 保持部にセンサが保持された樹脂体の斜視図である。It is a perspective view of the resin body which held the sensor in the holding part. 実施形態に係るリアクトルの製造方法を説明するための図であり、保持部を有する樹脂体を成型する際のＸＺ断面図である。It is a figure for demonstrating the manufacturing method of the reactor which concerns on embodiment, and is the XZ sectional view at the time of molding the resin body which has a holding part. 実施形態に係るリアクトルの製造方法を説明するための図であり、保持部を有する樹脂体を成型する際のＸＹ断面図である。It is a figure for demonstrating the manufacturing method of the reactor which concerns on embodiment, and is XY sectional view at the time of molding the resin body which has a holding part. パーティングラインを示す樹脂体の斜視図である。It is a perspective view of the resin body which shows a parting line. 他の実施形態に係る製造方法を説明するための図であり、保持部を有する樹脂体を成型する際のＸＺ断面図である。It is a figure for demonstrating the manufacturing method which concerns on another Embodiment, and is the XZ sectional view at the time of molding the resin body which has a holding part. 従来の樹脂体及び保持部の構成を示す図である。It is a figure which shows the structure of the conventional resin body and a holding part. 従来の保持部の上面側から見た斜視図である。It is a perspective view seen from the upper surface side of the conventional holding part. 従来の保持部の底面側から見た斜視図である。It is a perspective view seen from the bottom surface side of the conventional holding part.

以下、図面を参照して、本発明の実施形態のリアクトルについて説明する。 Hereinafter, the reactor according to the embodiment of the present invention will be described with reference to the drawings.

［１．実施形態］
［１−１．概略構成］
図１は、実施形態に係るリアクトルの斜視図である。図１に示すように、本実施形態に係るリアクトル１は、樹脂モールドコア２〜４と、コイル５ａ、５ｂと、センサ６とを有し、Ｈ字形状を有する樹脂モールドコア２の脚部に、２つのコイル５ａ、５ｂがそれぞれ装着され、コイル５ａ、５ｂ間にセンサ６がそれぞれ挿入されて配置されている。センサ６は、ここでは温度センサであり、リアクトル１の温度を検出する。 [1. Embodiment]
[1-1. Outline configuration]
FIG. 1 is a perspective view of the reactor according to the embodiment. As shown in FIG. 1, the reactor 1 according to the present embodiment has resin mold cores 2 to 4, coils 5a and 5b, and a sensor 6, and is formed on the legs of the resin mold core 2 having an H shape. Two coils 5a and 5b are mounted, respectively, and a sensor 6 is inserted and arranged between the coils 5a and 5b, respectively. The sensor 6 is a temperature sensor here, and detects the temperature of the reactor 1.

［１−２．詳細構成］
リアクトル１が備える各部構成について、詳細に説明する。なお、説明の便宜上、コイル５ａ、５ｂの巻軸が延びる方向（以下、単に「巻軸方向」ともいう。）をＸ軸方向、Ｘ軸方向と直交するコイル５ａ、５ｂの横並びの方向をＹ軸方向、Ｘ軸方向及びＹ軸方向に直交する方向をＺ軸方向とする。また、Ｙ軸方向を左右方向、Ｚ軸方向を上下方向という。Ｙ軸の矢印が指す方を右側、その反対側を左側といい、Ｚ軸の矢印が指す方向を上、その反対側を下という。これらの方向は、リアクトル１の各構成の位置関係を示すための表現であり、リアクトル１が設置対象に設置された際の位置関係及び方向を限定するものではない。 [1-2. Detailed configuration]
Each part configuration included in the reactor 1 will be described in detail. For convenience of explanation, the direction in which the winding axes of the coils 5a and 5b extend (hereinafter, also simply referred to as "winding axis direction") is the X-axis direction, and the side-by-side direction of the coils 5a and 5b orthogonal to the X-axis direction is Y. The direction orthogonal to the axial direction, the X-axis direction, and the Y-axis direction is defined as the Z-axis direction. Further, the Y-axis direction is referred to as a left-right direction, and the Z-axis direction is referred to as a vertical direction. The side pointed by the Y-axis arrow is called the right side, the opposite side is called the left side, the direction pointed by the Z-axis arrow is called up, and the opposite side is called down. These directions are expressions for indicating the positional relationship of each configuration of the reactor 1, and do not limit the positional relationship and direction when the reactor 1 is installed on the installation target.

図２は、実施形態に係るリアクトルの分解斜視図である。図２に示すように、樹脂モールドコア２は、Ｈ字形状を有しており、コア部材と、このコア部材を被覆する樹脂体２０とを有する。樹脂体２０が被覆するコア部材は、圧粉磁心などの磁性体からなる２つのＴ字型コアの脚同士を向かい合わせてＨ形状を成す。そのため、樹脂体２０は、このコア部材に倣ってＨ字形状を有する。このようにＨ形状の４本の脚が、樹脂モールドコア２の脚部２１を構成する。 FIG. 2 is an exploded perspective view of the reactor according to the embodiment. As shown in FIG. 2, the resin mold core 2 has an H-shape, and has a core member and a resin body 20 that covers the core member. The core member covered with the resin body 20 forms an H shape with the legs of two T-shaped cores made of a magnetic material such as a dust core facing each other. Therefore, the resin body 20 has an H-shape following the core member. In this way, the four H-shaped legs form the leg portion 21 of the resin mold core 2.

樹脂モールドコア３、４は、コア部材と、コア部材を被覆する樹脂体３０、４０とを有する。樹脂体３０、４０が被覆するコア部材は、直方体形状を有するブロック型の圧粉磁心などの磁性体である。そのため、樹脂体３０、４０は、このコア部材に倣って概略直方体形状を有する。樹脂体３０、４０の更なる詳細構成については後述する。 The resin mold cores 3 and 4 have a core member and resin bodies 30 and 40 that cover the core member. The core member covered with the resin bodies 30 and 40 is a magnetic material such as a block-type dust core having a rectangular parallelepiped shape. Therefore, the resin bodies 30 and 40 have a substantially rectangular parallelepiped shape following the core member. Further detailed configurations of the resin bodies 30 and 40 will be described later.

コイル５ａ、５ｂは、導線が巻回されてなり、筒状を成す。ここでは、リアクトル１は、一対のコイル５ａ、５ｂを二組有している。各組のコイル５ａ、５ｂは、樹脂モールドコア２の脚部２１に装着され、巻軸を平行にして横並びに配置されている。コイル５ａ、５ｂの間隔は、センサ６の厚みと同程度である。センサ６の厚みと同程度とは、センサ６がコイル５ａ、５ｂに接触しないでコイル５ａ、５ｂ間に挿入できる程度であり、センサ６の厚みの２倍未満である。コイル５ａ、５ｂの一端部同士は電気的に接続され、他端部は、リアクトル１の上方に引き出されている。 The coils 5a and 5b are formed by winding a conducting wire to form a tubular shape. Here, the reactor 1 has two sets of a pair of coils 5a and 5b. The coils 5a and 5b of each set are mounted on the legs 21 of the resin mold core 2 and are arranged side by side with the winding axes parallel to each other. The distance between the coils 5a and 5b is about the same as the thickness of the sensor 6. The same degree as the thickness of the sensor 6 means that the sensor 6 can be inserted between the coils 5a and 5b without contacting the coils 5a and 5b, and is less than twice the thickness of the sensor 6. One ends of the coils 5a and 5b are electrically connected to each other, and the other end is pulled out above the reactor 1.

樹脂モールドコア２の脚部２１にコイル５ａ、５ｂを装着した状態で、脚部２１の先端側から樹脂モールドコア３、４で挟み込むことで、リアクトル１が構成される。すなわち、樹脂モールドコア２〜４のコア部材が組み合わされることにより、概略θ形状の環状コアが形成されている。このようなリアクトル１において、外部電源からコイル５ａ、５ｂに電流が流れると、コイル５ａ、５ｂが磁束を発生させる。この磁束は、環状コアを構成するコア部材を通り、閉じた磁気回路を形成する。 With the coils 5a and 5b mounted on the legs 21 of the resin mold core 2, the reactor 1 is configured by sandwiching the coils 5a and 5b from the tip side of the legs 21 with the resin mold cores 3 and 4. That is, by combining the core members of the resin mold cores 2 to 4, an annular core having a substantially θ shape is formed. In such a reactor 1, when a current flows from an external power source to the coils 5a and 5b, the coils 5a and 5b generate magnetic flux. This magnetic flux passes through the core members that make up the annular core and forms a closed magnetic circuit.

樹脂体３０、４０は、コイル５ａ、５ｂの外側に配置されるコア部材を被覆する。樹脂体３０、４０には、開口が設けられており、この開口は、樹脂体２０から露出したコア部材の端面Ｅと接続される端面Ｅを露出させる。このコア部材は、樹脂モールドコア３、４のブロック型のコアである。 The resin bodies 30 and 40 cover the core members arranged outside the coils 5a and 5b. The resin bodies 30 and 40 are provided with openings, and the openings expose the end face E connected to the end face E of the core member exposed from the resin body 20. This core member is a block type core of the resin mold cores 3 and 4.

樹脂体３０、４０には、リアクトル１を設置対象に固定する固定部３４が設けられている。固定部３４は、ボルトが挿入される孔が設けられおり、ここではリアクトル１に二等辺三角形の頂点となる箇所にそれぞれ配置されている。ここでは、固定部３４は、樹脂体３０の上部中央に１つ設けられ、樹脂体４０の両端部に２つ設けられている。リアクトル１は、例えば、金属製のケースに収容され、固定部３４の孔に挿入されたボルトの締結によりケースに固定される。 The resin bodies 30 and 40 are provided with a fixing portion 34 for fixing the reactor 1 to the installation target. The fixing portion 34 is provided with a hole into which a bolt is inserted, and is arranged at a position at the apex of an isosceles triangle in the reactor 1. Here, one fixing portion 34 is provided in the center of the upper portion of the resin body 30, and two fixing portions 34 are provided at both ends of the resin body 40. The reactor 1 is housed in a metal case, for example, and is fixed to the case by fastening a bolt inserted into the hole of the fixing portion 34.

図２に示すように、センサ６は、検出部６１とリード線６２とを有する。検出部６１は、ここでは、柱状、より具体的には直方体形状を有し、リアクトル１の温度を検出する。検出部６１としては、例えば、温度変化に対して電気抵抗が変化するサーミスタを用いることができる。但し、検出部６１は、サーミスタに限定されず、磁気センサ、電流センサ、温度ヒューズなどのセンサとしても良い。リード線６２は、検出部６１に接続されており、検出部６１が出力する電気信号を、リアクトル１外部に伝送する信号線である。 As shown in FIG. 2, the sensor 6 has a detection unit 61 and a lead wire 62. Here, the detection unit 61 has a columnar shape, more specifically a rectangular parallelepiped shape, and detects the temperature of the reactor 1. As the detection unit 61, for example, a thermistor whose electrical resistance changes with respect to a temperature change can be used. However, the detection unit 61 is not limited to the thermistor, and may be a sensor such as a magnetic sensor, a current sensor, or a thermal fuse. The lead wire 62 is a signal line that is connected to the detection unit 61 and transmits an electric signal output by the detection unit 61 to the outside of the reactor 1.

図２に示すように、リアクトル１は、センサ６を保持する保持部７を備える。この保持部７は、一対のコイル５ａ、５ｂ間に設けられ、センサ６をＵ字状に取り囲んで保持する。保持部７は、樹脂体３０、４０のコア部材を被覆する部分と突き目なく一続きに形成されており、当該コア部材の他のコア部材、つまり樹脂モールドコア２のコア部材と接続される端面より巻軸方向（Ｘ軸方向）に離れて設けられている。換言すると、保持部７は、樹脂体３０、４０の一部の構成である。 As shown in FIG. 2, the reactor 1 includes a holding unit 7 that holds the sensor 6. The holding portion 7 is provided between the pair of coils 5a and 5b, and surrounds and holds the sensor 6 in a U shape. The holding portion 7 is formed seamlessly and continuously with the portion covering the core members of the resin bodies 30 and 40, and is connected to another core member of the core member, that is, the core member of the resin mold core 2. It is provided apart from the end face in the winding axis direction (X-axis direction). In other words, the holding portion 7 is a part of the resin bodies 30 and 40.

図３及び図４は、保持部７の構成を示す図であり、図３は、樹脂体３０、４０の側面図、図４は、樹脂体３０、４０の平面図である。図５は、保持部７にセンサ６が保持された樹脂体３０、４０の斜視図である。 3 and 4 are views showing the configuration of the holding portion 7, FIG. 3 is a side view of the resin bodies 30 and 40, and FIG. 4 is a plan view of the resin bodies 30 and 40. FIG. 5 is a perspective view of the resin bodies 30 and 40 in which the sensor 6 is held by the holding portion 7.

保持部７は、コイル５ａ、５ｂの間に設けられている。図３及び図４に示すように、保持部７は、一対の対向部７１、７２、連結部７３を有している。 The holding portion 7 is provided between the coils 5a and 5b. As shown in FIGS. 3 and 4, the holding portion 7 has a pair of facing portions 71 and 72 and a connecting portion 73.

一対の対向部７１、７２は、巻軸方向と平行な方向に対向して配置され、巻軸方向と交差するように一方向に延びて設けられている。ここでは、一対の対向部７１、７２は、上下方向に延び、センサ６が上方から挿入されるように検出部６１の厚み分、巻軸方向に離れて設けられている。対向部７１は、コア部材から近くに配置され、対向部７２は、コア部材から遠くに配置されている。 The pair of facing portions 71 and 72 are arranged so as to face each other in a direction parallel to the winding axis direction, and are provided so as to extend in one direction so as to intersect the winding axis direction. Here, the pair of facing portions 71 and 72 extend in the vertical direction and are provided apart in the winding axis direction by the thickness of the detection portion 61 so that the sensor 6 is inserted from above. The facing portion 71 is arranged near the core member, and the facing portion 72 is arranged far from the core member.

連結部７３は、一対の対向部７１、７２の端部を繋ぐ。ここでは、連結部７３は、巻軸方向に延び、その長さは検出部６１の厚み分である。一対の対向部７１、７２、及び連結部７３により、センサ６を取り囲むＵ字形状を構成する。 The connecting portion 73 connects the ends of the pair of facing portions 71 and 72. Here, the connecting portion 73 extends in the winding axis direction, and the length thereof is the thickness of the detecting portion 61. A pair of facing portions 71, 72 and a connecting portion 73 form a U-shape that surrounds the sensor 6.

具体的に本実施形態では、保持部７は、樹脂体３０、４０のコア部材を被覆する部分の中央部分から、巻軸方向に突出して設けられた略矩形状の板状体７０に、上下方向に延びて設けられたスリットとして構成される。一対の対向部７１、７２、連結部７３は、スリットを形成する板状体７０の縁部である。一対の対向部７１、７２及び連結部７３は、中実である。すなわち、一対の対向部７１、７２及び連結部７３は、樹脂で隙間なく構成されている。 Specifically, in the present embodiment, the holding portion 7 is vertically formed on a substantially rectangular plate-shaped body 70 provided so as to project in the winding axis direction from the central portion of the portion covering the core members of the resin bodies 30 and 40. It is configured as a slit provided extending in the direction. The pair of facing portions 71, 72 and the connecting portion 73 are edges of the plate-shaped body 70 forming a slit. The pair of facing portions 71, 72 and the connecting portion 73 are solid. That is, the pair of facing portions 71, 72 and the connecting portion 73 are made of resin without any gaps.

このように、保持部７は板状体７０のスリットとして構成されている。換言すると、保持部７は、コア部材を被覆する樹脂体３０、４０の部分と継ぎ目なく一続きに形成され、当該コア部材の端面Ｅより巻軸方向に離れて設けられている。当該コア部材の端面Ｅとは、樹脂体３０、４０から露出した面であり、他のコア部材と接続される面である。他のコア部材とは、本実施形態では、樹脂モールドコア２のＴ字型コアである。 In this way, the holding portion 7 is configured as a slit of the plate-shaped body 70. In other words, the holding portion 7 is seamlessly formed in succession with the portions of the resin bodies 30 and 40 that cover the core member, and is provided apart from the end surface E of the core member in the winding axis direction. The end surface E of the core member is a surface exposed from the resin bodies 30 and 40 and is a surface connected to other core members. The other core member is the T-shaped core of the resin mold core 2 in the present embodiment.

一対の対向部７１、７２には、一対の突起７４が設けられている。一対の突起７４は、対向部７１、７２の連結部７３とは反対側の端部に設けられている。対向部７１に設けられた突起７４は、対向部７２に向かって突出し、対向部７２に設けられた突起７４は、対向部７１に向かって突出しており、センサ６が挿入される保持部７の挿入口を狭めている。すなわち、センサ６が上方から保持部７に挿入されて保持されると、センサ６が上方に抜けようとしても、検出部６１の後端が突起７４に当接し、センサ６の抜けが防止される。 A pair of protrusions 74 are provided on the pair of facing portions 71 and 72. The pair of protrusions 74 are provided at the ends of the facing portions 71 and 72 on the opposite side of the connecting portion 73. The protrusion 74 provided on the facing portion 71 protrudes toward the facing portion 72, and the protrusion 74 provided on the facing portion 72 protrudes toward the facing portion 71, and the holding portion 7 into which the sensor 6 is inserted is inserted. The insertion slot is narrowed. That is, when the sensor 6 is inserted into the holding portion 7 from above and held, even if the sensor 6 tries to come off upward, the rear end of the detection unit 61 comes into contact with the protrusion 74, and the sensor 6 is prevented from coming off. ..

この突起７４は、一対の対向部７１、７２が延びる方向において、連結部７３と重なって設けられている。ここでは、一対の突起７４と連結部７３は上下方向に重なっている。 The protrusion 74 is provided so as to overlap the connecting portion 73 in the direction in which the pair of facing portions 71 and 72 extend. Here, the pair of protrusions 74 and the connecting portion 73 overlap in the vertical direction.

保持部７には、突出部８が設けられている。突出部８は、コア部材の端面Ｅから遠い対向部７２に設けられている。具体的には、対向部７２の、もう一方の対向部７１と対向する側とは反対側に設けられている。突出部８は、巻軸方向に突出して設けられている。ここでは、突出部８は、略矩形状の板状体である。 The holding portion 7 is provided with a protruding portion 8. The protruding portion 8 is provided on the facing portion 72 far from the end surface E of the core member. Specifically, it is provided on the side of the facing portion 72 opposite to the side facing the other facing portion 71. The projecting portion 8 is provided so as to project in the winding axis direction. Here, the protruding portion 8 is a substantially rectangular plate-shaped body.

［１−３．製造方法］
本実施形態のリアクトル１の製造方法について、図６及び図７を用いて説明する。図６は、保持部７を有する樹脂体４０を成型する際のＸＺ断面図である。図７は、保持部７を有する樹脂体４０を成型する際のＸＹ断面図であり、図６のＡ−Ａラインで切った図４の領域Ｒの断面図である。リアクトル１の製造方法は、樹脂体成型工程、保持部成型工程、突出部成型工程、及び組立工程を有する。 [1-3. Production method]
The method for producing the reactor 1 of the present embodiment will be described with reference to FIGS. 6 and 7. FIG. 6 is an XZ cross-sectional view when molding the resin body 40 having the holding portion 7. FIG. 7 is an XY cross-sectional view when molding the resin body 40 having the holding portion 7, and is a cross-sectional view of the region R of FIG. 4 cut along the AA line of FIG. The method for manufacturing the reactor 1 includes a resin body molding step, a holding portion molding step, a protruding portion molding step, and an assembly step.

樹脂体成型工程は、樹脂体２０、３０、４０を成型し、樹脂モールドコア２〜４を形成する工程である。具体的には、樹脂体成型工程では、上下方向に分割された上型及び下型内にコア部材をセットし、樹脂を充填して樹脂体２０、３０、４０を成型する。 The resin body molding step is a step of molding the resin bodies 20, 30 and 40 to form the resin mold cores 2 to 4. Specifically, in the resin body molding step, the core member is set in the upper mold and the lower mold divided in the vertical direction, and the resin bodies are filled with resin to mold the resin bodies 20, 30 and 40.

保持部成型工程は、保持部７を成型する工程であり、樹脂体成型工程の際に、樹脂体３０、４０の一部として保持部７を成型する。突出部成型工程は、突出部８を成型する工程である。ここでは、保持部成型工程及び突出部成型工程は、樹脂体３０、４０を成型する樹脂体成型工程と一緒に実行される。樹脂体成型工程、保持部成型工程、及び突出部成型工程では、少なくとも２方向に離型する金型を用いて、樹脂体３０、４０、保持部７及び突出部８を成型する。 The holding portion molding step is a step of molding the holding portion 7, and during the resin body molding step, the holding portion 7 is molded as a part of the resin bodies 30 and 40. The protrusion molding step is a step of molding the protrusion 8. Here, the holding portion molding step and the protruding portion molding step are executed together with the resin body molding step of molding the resin bodies 30 and 40. In the resin body molding step, the holding portion molding step, and the protruding portion molding step, the resin bodies 30, 40, the holding portion 7, and the protruding portion 8 are molded by using a mold that separates in at least two directions.

例えば、樹脂体４０を成型する場合、図６に示すように、樹脂体４０は、樹脂体４０に倣った形状を内側に有する上下に分割された上型８１と下型８２により成型し、図６及び図７に示すように、保持部７及び突出部８は、保持部７及び突出部８に倣った形状を内側に有する左右に分割された左型８３と右型８４とにより成型する。 For example, when the resin body 40 is molded, as shown in FIG. 6, the resin body 40 is molded by the upper and lower molds 81 and the lower mold 82 having a shape similar to the resin body 40 on the inside, and is shown in FIG. As shown in 6 and FIG. 7, the holding portion 7 and the protruding portion 8 are molded by a left and right mold 83 and a right mold 84 having a shape similar to the holding portion 7 and the protruding portion 8 on the inside.

すなわち、下型８２にブロック型のコア部材Ｂを載置し、治具でコア部材Ｂの端面Ｅとその反対側の面とを挟むようにしてコア部材Ｂを固定する。また、２つの端面Ｅの間であって、当該端面Ｅが位置するコア部材Ｂの表面の手前に、左型８３及び右型８４をセットする。その後、下型８２の上端と上型８１の下端が当接するように、上方から上型８１を被せて上型８１と下型８２とを組み合わせる。このとき、上型８１と下型８２で組み合わされた金型は、コア部材Ｂの片面側において左右方向に貫通しており、この貫通してなる空間に左型８３及び右型８４が入り込んだ状態となる。これにより、金型８１〜８４により囲われる空間が閉塞する。このとき、左右の金型８３、８４は、板状体７０、突出部８の左右方向の長さである厚み分、離間させる。 That is, the block type core member B is placed on the lower mold 82, and the core member B is fixed so as to sandwich the end surface E of the core member B and the surface on the opposite side thereof with a jig. Further, the left mold 83 and the right mold 84 are set between the two end faces E and in front of the surface of the core member B on which the end face E is located. After that, the upper die 81 is covered from above so that the upper end of the lower die 82 and the lower end of the upper die 81 are in contact with each other, and the upper die 81 and the lower die 82 are combined. At this time, the mold combined with the upper mold 81 and the lower mold 82 penetrates in the left-right direction on one side of the core member B, and the left mold 83 and the right mold 84 enter the penetrating space. It becomes a state. As a result, the space surrounded by the molds 81 to 84 is closed. At this time, the left and right molds 83 and 84 are separated by the thickness of the plate-shaped body 70 and the protruding portion 8 in the left-right direction.

金型８１〜８４により囲われる空間が閉塞した状態では、コア部材Ｂが治具や下型８２に接している部分を除いて上型８１、下型８２と離間しており、例えば上型８１に設けられたゲートＧから樹脂が充填される。この樹脂は、図６の矢印で示すように、上下の金型８１、８２とコア部材Ｂとの隙間に流れ込むとともに、保持部７及び突出部８を成型する左右の金型８３、８４の隙間に流れ込む。このように金型８１〜８４内の閉塞空間に樹脂が充填され、固化されることで、樹脂体４０、保持部７（一対の対向部７１、７２、連結部７３、及び一対の突起７４）、及び突出部８が一体的に成型される。すなわち、樹脂体４０のコア部材Ｂを被覆する部分と保持部７と突出部８は、同じ樹脂で継ぎ目なく一続きに形成される。これにより、樹脂モールドコア４が形成される。なお、端面Ｅの周りにＸＹ平面、ＸＺ平面に拡がって設けられた矩形状の舌片４１（図５参照。）は、Ｘ軸方向にスライドする金型（以下、前型という。）により形成される。 When the space surrounded by the molds 81 to 84 is closed, the core member B is separated from the upper mold 81 and the lower mold 82 except for the portion in contact with the jig and the lower mold 82. For example, the upper mold 81 The resin is filled from the gate G provided in. As shown by the arrows in FIG. 6, this resin flows into the gap between the upper and lower molds 81 and 82 and the core member B, and the gap between the left and right molds 83 and 84 for molding the holding portion 7 and the protruding portion 8. Flow into. As the closed space in the molds 81 to 84 is filled with resin and solidified in this way, the resin body 40 and the holding portion 7 (a pair of facing portions 71 and 72, a connecting portion 73, and a pair of protrusions 74) are formed. , And the protruding portion 8 are integrally molded. That is, the portion of the resin body 40 that covers the core member B, the holding portion 7, and the protruding portion 8 are seamlessly and continuously formed of the same resin. As a result, the resin mold core 4 is formed. The rectangular tongue piece 41 (see FIG. 5) provided around the end face E in the XY plane and the XZ plane is formed by a mold (hereinafter referred to as a front mold) that slides in the X-axis direction. Will be done.

図８に示すように、保持部７を構成する板状体７０、一対の対向部７１、７２、連結部７３、突起７４、及び突出部８の中央部分には、パーティングラインＬが形成される。このパーティングラインＬは、左右の金型８３、８４を合わせた際の左右の境界に形成される出っ張りである。 As shown in FIG. 8, a parting line L is formed at the central portion of the plate-shaped body 70 constituting the holding portion 7, the pair of facing portions 71 and 72, the connecting portion 73, the protrusion 74, and the protruding portion 8. To. The parting line L is a protrusion formed at the left and right boundary when the left and right molds 83 and 84 are combined.

また、保持部成型工程は、上下離型工程、左右離型工程を有する。すなわち、樹脂体４０、保持部７、及び突出部８を成型した後、前型を樹脂モールドコア４から離型する。そして、上下の金型８１、８２を樹脂モールドコア４から離型する。例えば、上型８１を上方に離型させて、樹脂モールドコア４の上方を開放し、下型８２に上下に貫通したピンにより樹脂モールドコア４を押し上げて下型８２から離型させる。このとき、左右の金型８３、８４は、樹脂モールドコア４にセットされたままである。 Further, the holding portion molding step includes a vertical mold release step and a left and right mold release step. That is, after molding the resin body 40, the holding portion 7, and the protruding portion 8, the front mold is released from the resin mold core 4. Then, the upper and lower molds 81 and 82 are released from the resin mold core 4. For example, the upper mold 81 is released upward to open the upper part of the resin mold core 4, and the resin mold core 4 is pushed up by a pin penetrating the lower mold 82 up and down to be released from the lower mold 82. At this time, the left and right molds 83 and 84 are still set in the resin mold core 4.

上下の金型８１、８２を離型させた後、左右の金型８３、８４を樹脂モールドコア４から離型して、樹脂モールドコア４を取り出す。上記と同様にして、樹脂体３０を成型して樹脂モールドコア３を作製する。 After the upper and lower molds 81 and 82 are released, the left and right molds 83 and 84 are released from the resin mold core 4 and the resin mold core 4 is taken out. In the same manner as described above, the resin body 30 is molded to produce the resin mold core 3.

ここで、突出部８を設けたことにより、突出部８が設けられていない従来技術と比べて、左右の金型８３、８４が離型しやすくなる。すなわち、突出部８を設けたことで、左右の金型８３、８４に接する樹脂量が多くなり、保持部７及び突出部８からなる全体としての樹脂の塊は大きくなる。樹脂の塊は、熱収縮、つまり当該樹脂が冷えて固化する際に収縮する。そして、樹脂の塊はその大きさが大きいほど、熱収縮による収縮量が大きくなる。そのため、成型された保持部７及び突出部８の左右の金型８３、８４に食い付くのを低減することができる。 Here, by providing the protruding portion 8, the left and right molds 83 and 84 can be easily separated from each other as compared with the conventional technique in which the protruding portion 8 is not provided. That is, by providing the protruding portion 8, the amount of resin in contact with the left and right molds 83 and 84 increases, and the overall resin mass composed of the holding portion 7 and the protruding portion 8 becomes large. The resin mass shrinks by heat, that is, when the resin cools and solidifies. The larger the size of the resin block, the larger the amount of shrinkage due to heat shrinkage. Therefore, it is possible to reduce the possibility of biting the left and right molds 83 and 84 of the molded holding portion 7 and the protruding portion 8.

組立工程は、作製された樹脂モールドコア２〜４とコイル５ａ、５ｂとを組み立ててリアクトル１を作製する工程である。具体的には、Ｈ字形状の樹脂モールドコア２の二対の脚部２１にコイル５ａ、５ｂをそれぞれ嵌め込み、この樹脂モールドコア２を樹脂モールドコア３、４でＸ軸方向の両側から挟んで、それぞれの樹脂体２０、３０、４０から露出したコア部材の端面同士を接続することでリアクトル１を作製する。このリアクトル１のコイル５ａ、５ｂの間のそれぞれに上方から検出部６１を挿入し、保持部７に差し込んでセンサ７をリアクトル１に装着する。 The assembling step is a step of assembling the manufactured resin mold cores 2 to 4 and the coils 5a and 5b to manufacture the reactor 1. Specifically, the coils 5a and 5b are fitted into the two pairs of legs 21 of the H-shaped resin mold core 2, and the resin mold cores 2 are sandwiched between the resin mold cores 3 and 4 from both sides in the X-axis direction. , The reactor 1 is manufactured by connecting the end faces of the core members exposed from the respective resin bodies 20, 30, and 40. A detection unit 61 is inserted from above between the coils 5a and 5b of the reactor 1 and inserted into the holding unit 7 to mount the sensor 7 on the reactor 1.

［１−４．作用・効果］
（１）本実施形態のリアクトル１は、巻軸を平行にして横並びに配置された一対のコイル５ａ、５ｂと、一対のコイル５ａ、５ｂの間に設けられ、センサ６をＵ字状に取り囲んで保持する保持部７と、コイル５ａ、５ｂの外側に配置されるコア部材を被覆する樹脂体３０（４０）と、を備え、保持部７は、コア部材を被覆する樹脂体３０（４０）の部分と継ぎ目なく一続きに形成され、コア部材の他のコア部材と接続される端面Ｅより巻軸方向に離れて設けられており、巻軸方向と平行な方向に対向して配置され、巻軸方向と交差するように一方向に延びる一対の対向部７１、７２と、一対の対向部７１、７２の端部を繋ぐ連結部７３と、を有し、少なくとも一方の対向部７１、７２には、連結部７３とは反対側の端部に、他方の対向部７１、７２に向かって突出する突起７４が設けられ、対向部７１、７２及び連結部７３を、中実にした。これにより、保持部７の強度を向上させ、生産性を向上させることができる。 [1-4. Action / effect]
(1) The reactor 1 of the present embodiment is provided between a pair of coils 5a and 5b and a pair of coils 5a and 5b arranged side by side with their winding axes parallel to each other, and surrounds the sensor 6 in a U shape. The holding portion 7 is provided with a holding portion 7 for covering the core member arranged outside the coils 5a and 5b, and the holding portion 7 is a resin body 30 (40) for covering the core member. It is formed seamlessly and continuously with the part of the core member, is provided away from the end surface E connected to the other core member of the core member in the winding axis direction, and is arranged so as to face the direction parallel to the winding axis direction. It has a pair of facing portions 71, 72 extending in one direction so as to intersect the winding axis direction, and a connecting portion 73 connecting the ends of the pair of facing portions 71, 72, and at least one of the facing portions 71, 72. Is provided with a protrusion 74 projecting toward the other facing portions 71 and 72 at the end opposite to the connecting portion 73, and the facing portions 71 and 72 and the connecting portion 73 are made solid. As a result, the strength of the holding portion 7 can be improved and the productivity can be improved.

（２）突起７４は、一対の対向部７１、７２に一対設けるようにした。これにより、センサ６の抜けを防止することができる。すなわち、従来のリアクトルでは、上下の金型で樹脂モールドコアを作製するため、保持部１０７の形状を上下方向にアンダーカットにならない形状にする必要があった。従来の保持部１０７では、センサ６の抜けを防止するために、対向部１７１、１７２に突起１７４を設けることで、センサ６が抜けようとしてもセンサ６の後端が突起１７４に当接させてセンサ６の抜けを抑制していた。 (2) A pair of protrusions 74 are provided on the pair of facing portions 71 and 72. As a result, it is possible to prevent the sensor 6 from coming off. That is, in the conventional reactor, since the resin mold core is manufactured by the upper and lower molds, it is necessary to make the shape of the holding portion 107 into a shape that does not undercut in the vertical direction. In the conventional holding portion 107, in order to prevent the sensor 6 from coming off, the protrusions 174 are provided on the facing portions 171 and 172 so that the rear end of the sensor 6 comes into contact with the protrusion 174 even if the sensor 6 is about to come off. The disconnection of the sensor 6 was suppressed.

この突起１７４は、連結部１７３と上下方向に重なり合わないように形成されている。すなわち、連結部１７３の突起１７４が上下方向に重なり合う部分は、中空にせざるをえず、このように対向部１７１、１７２の強度を考えると、片方の対向部１７２にしか突起１７４が設けられず、センサ６が抜け易いという問題があった。 The protrusion 174 is formed so as not to overlap the connecting portion 173 in the vertical direction. That is, the portion where the protrusion 174 of the connecting portion 173 overlaps in the vertical direction must be hollow, and considering the strength of the facing portions 171 and 172 in this way, the protrusion 174 is provided only on one facing portion 172. , There is a problem that the sensor 6 is easily pulled out.

これに対し、本実施形態では、上下に離型する金型８１、８２だけでなく、左右に離型する金型８３、８４を用いる方法により保持部７を形成するので、突起７４と連結部７３の上下方向の重なりを気にする必要ない。そのため、保持部７の形状の自由度を高めることができる。本実施形態では両方の対向部７１、７２に突起７４を設けているので、センサ６の抜けをより抑制することができる。 On the other hand, in the present embodiment, since the holding portion 7 is formed by a method using not only the molds 81 and 82 that are separated vertically but also the molds 83 and 84 that are separated left and right, the protrusion 74 and the connecting portion are formed. There is no need to worry about the vertical overlap of 73. Therefore, the degree of freedom in the shape of the holding portion 7 can be increased. In the present embodiment, since the protrusions 74 are provided on both the facing portions 71 and 72, it is possible to further suppress the sensor 6 from coming off.

（３）一対の突起７４は、一対の対向部７１、７２が延びる方向において、連結部７３と重なって設けるようにした。これにより、対向部７１、７２が延びる方向において、センサ６の位置を規制することができる。 (3) The pair of protrusions 74 are provided so as to overlap the connecting portion 73 in the direction in which the pair of facing portions 71 and 72 extend. As a result, the position of the sensor 6 can be regulated in the direction in which the facing portions 71 and 72 extend.

（４）コア部材の端面Ｅから遠い方の対向部７１、７２の、もう一方の対向部７１、７２と対向する側とは反対側に、巻軸方向に突出した突出部８を設けるようにした。これにより、保持部７及び突出部８全体としての樹脂の塊が大きくなり、熱収縮による収縮量を大きくすることができる。その結果、左右の金型８３、８４への保持部７（特に対向部７２、連結部７３）の食い付きを低減することができ、左右の金型８３、８４を離型しやすくすることができる。そのため、左右の金型８３、８４の離型の際に保持部７が破損することを防止でき、生産性を向上させることができる。また、センサ６を保持部７に挿入する際に、突出部８をつまんで挿入口を広げてセンサ６を挿入しやすくできるので、作業者の生産効率を向上させることができる。 (4) A protruding portion 8 protruding in the winding axis direction is provided on the opposite side of the facing portions 71 and 72 far from the end surface E of the core member, on the side opposite to the side facing the other facing portions 71 and 72. did. As a result, the resin mass of the holding portion 7 and the protruding portion 8 as a whole becomes large, and the amount of shrinkage due to heat shrinkage can be increased. As a result, it is possible to reduce the bite of the holding portions 7 (particularly the facing portions 72 and the connecting portions 73) to the left and right molds 83 and 84, and it is possible to easily separate the left and right molds 83 and 84. it can. Therefore, it is possible to prevent the holding portion 7 from being damaged when the left and right molds 83 and 84 are released, and it is possible to improve the productivity. Further, when the sensor 6 is inserted into the holding portion 7, the protruding portion 8 can be pinched to widen the insertion opening so that the sensor 6 can be easily inserted, so that the production efficiency of the operator can be improved.

（５）本実施形態のリアクトル１の製造方法は、巻軸を平行にして横並びに配置された一対のコイル５ａ、５ｂと、一対のコイル５ａ、５ｂの間に設けられ、センサ６をＵ字状に取り囲んで保持する保持部７と、コイル５ａ、５ｂの外側に配置されるコア部材を被覆する樹脂体３０（４０）と、有するリアクトル１の製造方法であって、保持部７は、コア部材の他のコア部材と接続される端面より巻軸方向に離れて設けられ、巻軸方向と平行な方向に対向して配置され、巻軸方向と交差するように一方向に延びる一対の対向部７１、７２と、一対の対向部７１、７２の端部を繋ぐ連結部７３と、を有し、巻軸の方向及び横並びの方向に直交する上下に分割された上型８１及び下型８２内にコア部材をセットし、樹脂を充填して樹脂体３０（４０）を成型する樹脂体成型工程と、樹脂体成型工程の際に、樹脂体３０（４０）の一部として、保持部７を、横並びの方向である左右に分割された左型８３及び右型８４により成型する保持部成型工程と、を備えるようにした。 (5) The method for manufacturing the reactor 1 of the present embodiment is provided between a pair of coils 5a and 5b and a pair of coils 5a and 5b arranged side by side with the winding axes parallel to each other, and the sensor 6 is U-shaped. A method for manufacturing a reactor 1 having a holding portion 7 that surrounds and holds the coil 5a, a resin body 30 (40) that covers a core member arranged outside the coils 5a and 5b, and the holding portion 7 is a core. A pair of opposing surfaces that are provided apart from the end face connected to the other core member of the member in the winding axis direction, are arranged to face each other in a direction parallel to the winding axis direction, and extend in one direction so as to intersect the winding axis direction. Upper mold 81 and lower mold 82 which have a portion 71, 72 and a connecting portion 73 connecting the ends of the pair of facing portions 71, 72, and which are vertically divided in the direction of the winding axis and the side-by-side direction During the resin body molding step of setting the core member inside and filling the resin to mold the resin body 30 (40) and the resin body molding step, the holding portion 7 is used as a part of the resin body 30 (40). Is provided with a holding portion molding step of molding by the left mold 83 and the right mold 84 divided into left and right in the side-by-side direction.

これにより、一対の対向部７１、７２及び連結部７３を中実にすることができるので、保持部７の破損を抑制できるリアクトル１を得ることができ、その結果、生産性を向上させることができる。 As a result, the pair of facing portions 71, 72 and the connecting portion 73 can be made solid, so that a reactor 1 capable of suppressing damage to the holding portion 7 can be obtained, and as a result, productivity can be improved. ..

（６）左型８３及び右型８４により、端面から遠い方の対向部７１、７２の、もう一方の対向部７１、７２と対向する側とは反対側に、巻軸方向に突出した突出部８を成型する突出部成型工程を備えるようにした。 (6) Due to the left mold 83 and the right mold 84, the protruding portions of the facing portions 71 and 72 far from the end face are projected in the winding axis direction on the side opposite to the other facing portions 71 and 72. A protrusion molding step for molding 8 is provided.

これにより、保持部７の破損を防止し、生産性を向上させることができる。すなわち、左右の金型８３、８４を離型する際に、突出部８を設けないと、保持部７が樹脂の塊として小さく、保持部７が左型８３、右型８４の何れかにひっついて離れづらい場合がある。この場合、無理に離型すると、連結部７３など保持部７に負荷がかかり保持部７の破損を招く虞がある。これに対し、本実施形態では、突出部成型工程により突出部８を設けるようにしたので、保持部７及び突出部８が全体として樹脂の塊が大きくなるので、当該樹脂が冷えた際に生じる収縮量を大きくすることができ、左右の金型８３、８４の食い付きを低減することができる。そのため、左右の金型８３、８４の離型が容易になり、保持部７の破損を防止することができる。その結果、生産性を向上させることができる。 As a result, the holding portion 7 can be prevented from being damaged and the productivity can be improved. That is, if the protruding portions 8 are not provided when the left and right molds 83 and 84 are released, the holding portion 7 is small as a lump of resin, and the holding portion 7 sticks to either the left mold 83 or the right mold 84. It may be difficult to separate. In this case, if the mold is forcibly released, a load may be applied to the holding portion 7 such as the connecting portion 73, which may cause damage to the holding portion 7. On the other hand, in the present embodiment, since the projecting portion 8 is provided by the projecting portion molding step, the holding portion 7 and the projecting portion 8 as a whole become a large mass of resin, which occurs when the resin is cooled. The amount of shrinkage can be increased, and the biting of the left and right molds 83 and 84 can be reduced. Therefore, the left and right molds 83 and 84 can be easily separated, and the holding portion 7 can be prevented from being damaged. As a result, productivity can be improved.

［２．他の実施形態］
本発明は、実施形態に限定されるものではなく、下記に示す他の実施形態も包含する。また、本発明は、実施形態及び下記の他の実施形態を全て又はいずれかを組み合わせた形態も包含する。さらに、これらの実施形態を発明の範囲を逸脱しない範囲で、種々の省略や置き換え、変更を行うことができ、その変形も本発明に含まれる。 [2. Other embodiments]
The present invention is not limited to the embodiments, but also includes other embodiments shown below. The present invention also includes an embodiment and a combination of all or any of the following other embodiments. Furthermore, various omissions, replacements, and changes can be made to these embodiments without departing from the scope of the invention, and modifications thereof are also included in the present invention.

（１）上記実施形態では、樹脂体３０、４０は、ブロック型のコア部材を被覆したが、コア部材としてＵ字型コアを被覆しても良い。Ｕ字形状の脚の先端面が樹脂体３０、４０から露出しており、他のコア部材と接続される端面となる。保持部７は、この端面よりも巻軸方向に離れて設けられている。左右に分割された金型で保持部７を成型するためである。 (1) In the above embodiment, the resin bodies 30 and 40 are coated with a block-shaped core member, but a U-shaped core may be coated as the core member. The tip surfaces of the U-shaped legs are exposed from the resin bodies 30 and 40, and serve as end faces connected to other core members. The holding portion 7 is provided so as to be separated from the end face in the winding axis direction. This is because the holding portion 7 is molded by the mold divided into left and right.

（２）上記実施形態では、突出部８は、左右の金型８３、８４により成型したが、左右に分割された別の左右の金型により成型しても良い。この場合、突出部８には、上下方向にパーティングラインＬが形成される。また、左右の金型８３、８４は、上型８１と下型８２に連動し、保持部７及び突出部８を成型する左右一対の金属ブロックを左右方向にスライドさせるスライド機構により構成しても良い。当該金属ブロックは、上型８１と下型８２の動きとともに左右に動いても良いし、上型８１と下型８２の動きの後に動くようにしても良い。 (2) In the above embodiment, the protruding portion 8 is molded by the left and right molds 83 and 84, but may be molded by another left and right molds divided into left and right. In this case, a parting line L is formed in the protruding portion 8 in the vertical direction. Further, the left and right molds 83 and 84 may be configured by a slide mechanism that is interlocked with the upper mold 81 and the lower mold 82 and slides a pair of left and right metal blocks for molding the holding portion 7 and the protruding portion 8 in the left-right direction. good. The metal block may move left and right with the movement of the upper die 81 and the lower die 82, or may move after the movement of the upper die 81 and the lower die 82.

また、図９に示すように、上下の金型８１、８２により成型しても良い。この場合、突出部８には、上下に分割するパーティングラインＬが形成される。但し、上記実施形態によれば、上下の金型８１、８２により樹脂体３０、４０も突出部８も成型できるので金型の数を少なくすることができ、生産コストを削減することができる。また、上下の金型８１、８２とは独立した上下に分割された金型により成型しても良い。この場合、突出部８には、上下に分割するパーティングラインＬが形成される。 Further, as shown in FIG. 9, it may be molded by the upper and lower dies 81 and 82. In this case, the protruding portion 8 is formed with a parting line L that is vertically divided. However, according to the above embodiment, since the resin bodies 30, 40 and the protruding portion 8 can be molded by the upper and lower dies 81 and 82, the number of dies can be reduced and the production cost can be reduced. Further, it may be molded by a mold divided into upper and lower parts independent of the upper and lower molds 81 and 82. In this case, the protruding portion 8 is formed with a parting line L that is vertically divided.

（３）上記実施形態では、一対の対向部７１、７２は、巻軸方向及び横並び方向に直交する上下方向に延びて設けたが、巻軸方向と交差するように設けても良い。この場合、センサ６の検出部６１は、保持部７により上下方向に対して斜めの状態で保持される。そのため、検出部６１の長さが長い場合であっても、上下方向と平行に保持する実施形態よりもリアクトル１を低背化することができる。 (3) In the above embodiment, the pair of facing portions 71 and 72 are provided so as to extend in the vertical direction orthogonal to the winding axis direction and the side-by-side arrangement direction, but may be provided so as to intersect the winding axis direction. In this case, the detection unit 61 of the sensor 6 is held by the holding unit 7 in an oblique state with respect to the vertical direction. Therefore, even when the length of the detection unit 61 is long, the height of the reactor 1 can be made lower than that of the embodiment in which the detection unit 61 is held in parallel with the vertical direction.

１リアクトル
２〜４樹脂モールドコア
２０樹脂体
２１脚部
３０樹脂体
３４固定部
４０樹脂体
４１舌片
５ａ、５ｂコイル
６センサ
６１検出部
６２リード線
７保持部
７０板状体
７１、７２対向部
７３連結部
７４突起
８突出部
８１上型
８２下型
８３左型
８４右型
Ｅ端面 1 Reactor 2-4 Resin mold core 20 Resin body 21 Leg 30 Resin body 34 Fixing part 40 Resin body 41 Tongue piece 5a, 5b Coil 6 Sensor 61 Detection part 62 Lead wire 7 Holding part 70 Plate-shaped body 71, 72 Opposing part 73 Connecting part 74 Protrusion 8 Protruding part 81 Upper type 82 Lower type 83 Left type 84 Right type E End face

Claims

A pair of coils arranged side by side with their winding axes parallel,
A holding portion provided between the pair of coils and holding the sensor in a U shape.
A resin body that covers the core member arranged on the outside of the coil and
With
The holding portion is seamlessly formed with the portion of the resin body that covers the core member, and is provided apart from the end surface connected to the other core member of the core member in the winding axis direction. ,
A pair of facing portions that are arranged to face each other in a direction parallel to the winding axis direction and extend in one direction so as to intersect the winding axis direction.
A connecting portion that connects the ends of the pair of facing portions and
Have,
At least one of the facing portions is provided with a protrusion at an end opposite to the connecting portion, which projects toward the other facing portion.
The facing portion and the connecting portion are solid.
Reactor featuring.

The protrusions are provided on the pair of facing portions.
1. The reactor according to claim 1.

The protrusion is provided so as to overlap the connecting portion in the direction in which the pair of facing portions extend.
2. The reactor according to claim 2.

A protruding portion protruding in the winding axis direction is provided on the side of the facing portion far from the end face, which is opposite to the side facing the other facing portion.
The reactor according to any one of claims 1 to 3.

The core member has a rectangular parallelepiped shape or a U-shape.
The reactor according to any one of claims 1 to 4.

A pair of coils arranged side by side with their winding axes parallel to each other, a holding portion provided between the pair of coils and holding the sensor in a U shape, and a core arranged outside the coils. It is a method of manufacturing a resin body that covers a member and a reactor that has it.
The holding part is
It is provided apart from the end face connected to the other core member of the core member in the winding axis direction.
A pair of facing portions that are arranged to face each other in a direction parallel to the winding axis direction and extend in one direction so as to intersect the winding axis direction.
A connecting portion that connects the ends of the pair of facing portions and
Have,
A resin body molding step of setting the core member in the upper and lower molds divided into upper and lower molds orthogonal to the direction of the winding shaft and the side-by-side direction, filling the resin body, and molding the resin body.
During the resin body molding step, a holding portion molding step of molding the holding portion as a part of the resin body by a left mold and a right mold divided into left and right in the side-by-side direction.
To prepare
A method for manufacturing a reactor characterized by.

The winding shaft is formed on a side of the facing portion far from the end face, which is opposite to the other facing side, by a mold divided into upper and lower or left and right other than the left mold and the right mold. Providing a protrusion molding process for molding a protrusion protruding in the direction,
The method for producing a reactor according to claim 6, wherein the reactor is produced.