JP5365305B2 - Resin mold core and reactor - Google Patents

Resin mold core and reactor Download PDF

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JP5365305B2
JP5365305B2 JP2009083064A JP2009083064A JP5365305B2 JP 5365305 B2 JP5365305 B2 JP 5365305B2 JP 2009083064 A JP2009083064 A JP 2009083064A JP 2009083064 A JP2009083064 A JP 2009083064A JP 5365305 B2 JP5365305 B2 JP 5365305B2
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resin mold
core
mold core
resin
gap plate
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JP2010238798A (en
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真二郎 三枝
昌揮 杉山
修一 平田
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トヨタ自動車株式会社
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a technique for effectively preventing cracks of a core during contraction of resin, when the high temperature at molding the resin is lowered to a room temperature in a resin mold core, thereby improving the yield. <P>SOLUTION: A U-shaped resin mold core includes a plurality of magnetic cores 24, 26 and 28, and a plurality of non-magnetic gap plates 30, which are alternately adjacent to each other, and the plurality of magnetic cores 24, 26 and 28, and the plurality of non-magnetic gap plates 30 are molded by resin from outside. The outer peripheral edges of the gap plates 30 are located outside of the respective outer peripheral edges of the cores 24, 26 and 28 contacting the respective gap plates 30. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  In the present invention, a plurality of cores made of a magnetic material and a plurality of gap plates made of a nonmagnetic material are alternately arranged adjacent to each other, and the plurality of cores and the gap plates are molded from the outside with a resin. The present invention relates to a resin mold core.

  Conventionally, for example, in a vehicle equipped with a rotating electrical machine such as an electric vehicle or a hybrid vehicle, the rotating electrical machine drive device is configured by providing an inverter or a booster circuit between the rotating electrical machine and a power supply device such as a secondary battery. It is considered to be. The booster circuit includes a switching element and a reactor connected to the switching element, and the reactor includes a core made of a magnetic material such as an iron core and a dust core, and a coil wound around the core. The booster circuit can control the power storage in the reactor by controlling the ON time and the OFF time of the switching element, and can boost the voltage supplied from the power source to an arbitrary voltage and supply it to the inverter. . Further, the reactor may be used as a transformer element or a noise filter in an electric circuit.

  In the case of a reactor used in such a booster circuit or the like, if the current flowing through the coil increases and the core is magnetically saturated, magnetic energy cannot be stored, making it difficult to effectively perform the reactor function. . For this reason, in the reactor, at least two cores made of a magnetic material are opposed to each other through a gap plate made of a non-magnetic material, and a coil is wound around the core to improve the linearity of the BH characteristic. Thus, it is conceivable that magnetic saturation of the core is less likely to occur. In such a configuration, even if the magnetic permeability of the core is lowered and the current flowing through the coil is increased, it is difficult for the magnetic resistance to increase due to the magnetic saturation of the core, and the reactor inductance is prevented from excessively decreasing. There is a possibility.

  In Patent Document 1, a gap of a plate-like member formed of ceramic is inserted between magnetic bodies constituting a core, and the cross-sectional size of the gap is larger than the size of the end surfaces of the magnetic bodies on both sides thereof. It describes a core in which the magnetic body and the gap are bonded by applying an adhesive to the outer periphery of the contact portion between the magnetic body and the gap, and a reactor using the core.

  Patent Document 2 discloses a gap portion in which a plurality of core materials are connected via a spacer, a coil provided around the outer periphery of a coil bobbin, and a spacer provided between adjacent core materials. Reactors including a resin that functions as a holding member that holds the core material so as to cover a part or the whole of each of the above are described.

JP 2006-294830 A JP 2008-78219 A

  As described above, in order to make the magnetic saturation of the core difficult to occur, at least two cores made of a magnetic material are opposed to each other through a gap plate made of a nonmagnetic material in the reactor, and a coil is wound around the core. In the structure to mount, it is also conceivable that the core and the gap plate are resin-molded, that is, covered with resin. According to such a configuration, the bonding strength between the core and the gap plate can be increased, the mechanical strength can be increased, and the coil and the core can be easily insulated. Further, since the dust core easily breaks and breaks, it can be protected from an impact caused by an external force. However, in the case of such a configuration, the gap plate is originally used by being joined to a core made of a magnetic material such as a dust core, and the interval between the two cores located on both sides of the gap plate is set in the magnetic path direction. Since it is provided to maintain a predetermined interval set in advance, there is no other shape restriction. For this reason, conventionally, the gap plate is made as small as possible in order to reduce the amount of material used and reduce costs, and from the viewpoint of workability when joining the gap plate to the core, the same cross-sectional area as the core is used. It is considered to use a gap plate having the same area as the core at the joint with the core.

  For example, a plurality of cores made of a powder magnetic core are formed by compression molding a powder of a metal or metal oxide soft magnetic material such as iron, and a non-ceramic or resin core is formed between two cores. It is conceivable to form a core gap plate assembly (core magnetic core) by bonding gap plates made of a magnetic material with an adhesive or the like. Then, in order to ensure insulation of the core gap plate assembly from the coil and improve the mechanical strength, the core gap plate assembly is molded with a resin bobbin to constitute a resin mold core. As the material of the resin bobbin, a thermoplastic resin such as polybutylene terephthalate (PBT) or polyphenylene sulfide (PPS) is used, and is thermally deformed at a temperature of 200 ° C. or higher. Then, the core gap plate assembly is injection-molded into a predetermined shape by injecting a resin into the mold with the core gap plate assembly installed in the mold. As a result, the core gap plate assembly is resin-molded to form a resin-molded core. However, when injection molding is performed with a part of the core gap plate abutting against the inner surface of the mold, a part of the core is exposed to the outside without being molded into the resin. It cannot be said that there is no possibility of occurrence. That is, when the core gap plate assembly is injection-insert molded with the resin constituting the resin bobbin and then taken out from the mold, the resin heated to a high temperature of 200 ° C. or more is lowered to room temperature and cooled and cured. As the resin contracts, tensile stress acts on the core surface. In particular, when the resin shrinks, a high tensile stress is applied to the boundary between the resin and the core end surface exposed from the resin, so it cannot be said that there is no possibility that the core surface will crack. In particular, such cracks tend to occur when the core is made of a dust core.

  When cracks occur in the core in this way, the effective magnetic permeability of the core decreases, and the inductance of the reactor formed by the resin mold core also decreases. When the inductance decreases, there is a possibility that functions required for the reactor as an electrical component such as a transformer element cannot be effectively exhibited. For this reason, there is room for improvement in terms of yield improvement.

  On the other hand, in the case of the core described in Patent Document 1, in the case of the reactor described in Patent Document 2 instead of the resin-molded core, the resin heated to a high temperature drops to room temperature. It is not considered to prevent the core from cracking during cooling and hardening.

  When forming an annular resin mold core, first, a pair of U-shaped resin mold cores are made, and both ends of the U-shaped resin mold core are joined to both ends of the mating resin mold core via a gap plate. Is also possible. In this case, a part of the core is exposed to the outside at both end faces of each U-shaped resin mold core. Even when such a U-shaped resin mold core is manufactured, the same disadvantage as described above may occur.

  An object of the present invention is to effectively prevent a core crack at the time of resin shrinkage when a high-temperature resin at the time of molding is lowered to room temperature in a resin mold core and a reactor, thereby improving yield.

The resin mold core according to the present invention includes a gap plate made of a non-magnetic material disposed between a plurality of cores made of a magnetic material, and is configured by molding the plurality of cores and the gap plate with resin from the outside. In the resin mold core, the gap plate is formed by positioning at least a part of the outer peripheral edge outside the outer peripheral edge of the core contacting the gap plate, and is for resin shrinkage suppression covered with the resin. A resin mold core having a protruding portion.

According to the above resin mold core, even when resin shrinkage occurs when the high temperature resin during molding drops to room temperature, the gap that protrudes outward from the outer periphery of the core is applied to the entire resin. It can suppress by the protrusion part of a board. For this reason, the stress applied to the boundary between the core and the resin can be reduced, cracks can be effectively prevented from occurring on the core surface, and the yield can be improved. Therefore, it is possible to suppress the decrease in inductance of the reactor constituted by the resin mold core, and to effectively exhibit the function required for the reactor as an electrical component such as a transformer element.

In the resin mold core according to the present invention, preferably, at least a part of the plurality of cores has an end exposed surface that is provided at the end and is exposed to the outside by being not covered with the resin .

According to the above resin mold core, the gap plate is formed by positioning at least a part of the outer peripheral edge outside the outer peripheral edge of the core that contacts the gap plate, and the resin shrinkage suppression covered with the resin. If the structure of the present invention is not employed, the stress at the boundary between the end exposed surface and the resin is applied due to the resin shrinkage when the high temperature resin during molding drops to room temperature. It is easy to cause cracks on the core surface. For this reason, the effect acquired by employ | adopting the structure of this invention becomes more remarkable.

  In the resin mold core according to the present invention, preferably, the plurality of cores are made of a magnetic core obtained by combining powder particles of a metal-based material such as a dust core.

According to the above resin mold core, the gap plate is formed by positioning at least a part of the outer peripheral edge outside the outer peripheral edge of the core that contacts the gap plate, and the resin shrinkage suppression covered with the resin. In the case where the configuration of the present invention that has the protrusions for use is not adopted, cracks are likely to occur on the core surface due to resin shrinkage when the high-temperature resin during molding drops to room temperature. For this reason, the effect acquired by employ | adopting the structure of this invention becomes more remarkable.

  In the resin mold core according to the present invention, preferably, the gap plate is formed with a hole portion penetrating in the axial direction in the center portion.

  According to said resin mold core, the material of a gap board can be reduced and cost reduction can be aimed at.

  In the resin mold core according to the present invention, preferably, the gap plate is formed in a circular cross section.

  According to said resin mold core, the material of a gap board can be reduced and cost reduction can be aimed at.

  The resin mold core according to the present invention preferably includes an inner gap plate disposed inside the gap plate via a gap.

  According to said resin mold core, it can suppress more effectively that the shape of the whole resin mold core varies, reducing the material of a gap board. In addition, even when the end face of the core facing the gap plate is not a flat surface whose height differs between the center and the end, the resin mold can be obtained by appropriately changing the thickness of the gap plate and the inner gap plate. It is possible to more effectively suppress the variation in the shape of the entire core.

  Moreover, in the resin mold core according to the present invention, preferably, the gap plate has a protruding portion that protrudes outward from the core-side linear outer peripheral edge constituting the outer peripheral edge of the core, and the protruding portion is the core The gap plate side linear outer peripheral edge portion is parallel to the side linear outer peripheral edge portion, and the width in the direction orthogonal to the arrangement direction of the plurality of cores of the gap plate side linear outer peripheral edge portion is the core side linear outer peripheral portion. It has the magnitude | size of 1/4 or more of the width | variety of a peripheral part.

  According to said resin mold core, resin contraction can be suppressed by a gap plate, and it can suppress more effectively that a crack arises on the core surface.

  Moreover, in the resin mold core according to the present invention, preferably, the gap plate has a protruding portion that protrudes outward from the core-side linear outer peripheral edge constituting the outer peripheral edge of the core, and the protruding portion is the core The gap plate side linear outer peripheral edge portion is parallel to the side linear outer peripheral edge portion, and the protruding height of the protruding portion from the core side linear outer peripheral edge portion is 0.4 mm or more.

  According to said resin mold core, resin contraction can be suppressed by a gap plate, and it can suppress more effectively that a crack arises on the core surface.

  Moreover, in the resin mold core according to the present invention, preferably, the gap plate has a protruding portion that protrudes outward from the core-side linear outer peripheral edge constituting the outer peripheral edge of the core, and the protruding portion is the core Gap with respect to the direction orthogonal to the arrangement direction of the core, having a gap plate side linear outer peripheral edge parallel to the side linear outer peripheral edge, and continuing the resin on both sides of the protrusion at the outer portion of the protrusion. The minimum thickness of the resin on the outer side from the plate-side linear outer peripheral edge has a size of 1 mm or more.

  According to said resin mold core, the intensity | strength of a resin part can be improved more effectively.

  In the resin mold core according to the present invention, preferably, the gap plate includes a plurality of small protrusions provided on both side surfaces facing the core so as to protrude in the thickness direction.

  According to the above resin mold core, even when the end surface of the core facing the gap plate is not a flat surface, the area of the contact portion between the gap plate and the end surface of the core can be reduced, and the gap plate is less inclined to the core. Further, it is possible to more effectively suppress the variation of the entire shape of the resin mold core.

  Moreover, in the resin mold core according to the present invention, preferably, the gap plate is provided on the both sides in the thickness direction of the protruding portion, the protruding portion protruding outward from the outer peripheral edge of the core, and the position of the core with respect to the gap plate And a guide part for suppressing displacement.

  According to the resin mold core described above, the gap plate is disposed between the two cores while maintaining a predetermined positional relationship between the two cores and the gap plate before the resin mold of the resin mold core. As a result, the work of combining them can be performed more easily.

  Moreover, the reactor which concerns on this invention is a reactor characterized by including the resin mold core which concerns on this invention, and the coil wound around the resin mold core.

The reactor according to the present invention includes an annular resin mold core formed by joining a pair of resin mold cores according to the present invention each formed in a U shape, and a pair of I shapes on both sides of the annular resin mold core. a reactor, characterized in that it comprises a coil wound around each of the parts.

  According to the resin mold core and the reactor according to the present invention, it is possible to effectively prevent the core cracking at the time of resin shrinkage when the high temperature resin at the time of molding is lowered to room temperature, and the yield can be improved.

It is a perspective view which shows the reactor comprised by the U-shaped resin mold core which is the resin mold core of the 1st Embodiment of this invention. It is a perspective view which takes out and shows one U-shaped resin mold core which comprises the reactor of FIG. It is a perspective view which shows the core gap board joined body before the resin mold which comprises the U-shaped resin mold core of FIG. It is A arrow directional view of FIG. It is AA sectional drawing of FIG. It is a perspective view which shows the core gap board assembly before resin mold which comprises one U-shaped resin mold core which comprises an example of the conventional example of a reactor. It is a figure corresponding to FIG. 5 which shows one U-shaped resin mold core which comprises an example of the conventional example of a reactor. It is a schematic perspective view which shows a mode that a crack generate | occur | produces by the resin shrinkage | contraction in the core surface in one U-shaped resin mold core which comprises one example of the conventional example of a reactor. It is a figure which shows the gap board which comprises the U-shaped resin mold core of the 2nd Embodiment of this invention. It is a figure corresponding to FIG. 4 which shows the core gap board assembly before the resin mold which comprises the U-shaped resin mold core of 2nd Embodiment. It is a figure corresponding to Drawing 5 showing the U-shaped resin mold core of a 2nd embodiment. It is a figure corresponding to FIG. 4 which shows the core gap board assembly before resin molding which comprises the U-shaped resin mold core of the 3rd Embodiment of this invention. It is a figure corresponding to FIG. 4 which shows the core gap board assembly before resin mold which comprises the U-shaped resin mold core of another 3 examples of embodiment of this invention. It is a perspective view which shows the I-shaped resin mold core which is the resin mold core of the 4th Embodiment of this invention in the state before a resin mold (a) and after a resin mold (b). It is a perspective view which shows the I-shaped resin mold core which is the resin mold core of the 5th Embodiment of this invention in the state before a resin mold (a), and after a resin mold (b). It is a perspective view which shows the I-shaped resin mold core which is the resin mold core of the 6th Embodiment of this invention in the state before a resin mold (a), and after a resin mold (b). It is a perspective view which shows the I-shaped resin mold core which is the resin mold core of the 7th Embodiment of this invention in the state before a resin mold. It is the figure which looked at the gap board which comprises the U-shaped resin mold core which is the resin mold core of the 8th Embodiment of this invention from (a) from the front direction, (b) from the side direction, respectively. . It is a figure corresponding to the AA section of Drawing 4 showing the U-shaped resin mold core of an 8th embodiment. It is a figure which shows the gap board of another 2 examples which comprise the U-shaped resin mold core of 8th Embodiment. It is sectional drawing of the gap board part which shows the core gap board assembly before the resin mold which comprises the U-shaped resin mold core which is the resin mold core of the 9th Embodiment of this invention. It is a figure corresponding to the BB section of Drawing 21 showing the U-shaped resin mold core of a 9th embodiment in the state after resin molding. It is a figure corresponding to the BB section of Drawing 21 showing the U-shaped resin mold core which is the resin mold core of a 10th embodiment of the present invention in the state after resin molding. It is the figure which took out the gap board which comprises the U-shaped resin mold core of 11th Embodiment, and was seen from the left-right direction of FIG.

[First Embodiment]
Hereinafter, a first embodiment of the present invention will be described in detail. FIG. 1 is a perspective view showing a reactor constituted by a U-shaped resin mold core, which is a resin mold core according to the first embodiment of the present invention. FIG. 2 is a perspective view showing one U-shaped resin mold core taken out of the reactor of FIG. FIG. 3 is a perspective view showing a core gap plate assembly before resin molding, which constitutes the U-shaped resin mold core of FIG. 2. 4 is a view taken in the direction of arrow A in FIG. 5 is a cross-sectional view taken along the line AA in FIG.

  As shown in FIG. 1, a reactor 10 according to the present embodiment includes an annular resin mold core 12 and a pair of coils wound around a pair of I-shaped portions facing each other. 14. The reactor 10 is used as, for example, a DC / DC converter constituting a motor drive device mounted on a hybrid vehicle including an engine and a traveling motor as a vehicle drive source, a transformer element of an electric circuit, a component part of a noise filter, and the like. To do.

  The annular resin mold core 12 includes a pair of U-shaped resin mold cores 16 that are formed in a substantially U shape, and a pair of U-shaped resin mold cores 16 that are not illustrated, and are made of a non-magnetic intermediate gap plate. It is comprised by joining via. As shown in FIG. 2, each U-shaped resin mold core 16 is formed in a substantially U shape, and the entire core gap plate assembly 18 other than the pair of end surfaces 20 formed in a substantially U shape is made of resin. The bobbin 22 is covered. That is, as shown in FIG. 3, the core gap plate assembly 18 includes a plurality of cores 24, 26, and 28 made of a magnetic material, and two cores 24, 26, and 28. In a state where a plurality of gap plates 30 arranged one by one are combined, the entire cores 24, 26, 28 and the gap plate 30 except for the pair of end surfaces 20 are molded with resin. In this state, as shown in FIG. 2, the U-shaped resin mold core 16 is made of resin around the cores 24, 26, 28 (see FIG. 3 for 26, 28) and the gap plate 30 (FIG. 3). Bobbins 22 are provided.

  More specifically, the core gap plate assembly 18 before resin molding shown in FIG. 3 includes a plurality of cores 24, 26, and 28 made of a magnetic material, which are magnetic cores such as dust cores of a metal-based material. A plurality of gap plates 30 made of magnetic material are alternately arranged adjacent to each other, and are joined together by an adhesive or the like. The magnetic material is not limited to the powder magnetic core, and each of the cores 24, 26 and 28 is made of pure iron, Fe-Si-based, Fe-Ni-based, Ni-Co-based metallic magnetic material, ferrite, etc. The magnetic core may be made of a magnetic core obtained by bonding powder particles of a metal-based material such as a metal oxide magnetic material under pressure, or sintering and heat-treating the powder particles. In the core gap plate assembly 18, the two cores 24 and 26 constituting both ends of the U-shaped portion are formed in a short column shape having a rectangular cross section. On the other hand, in the core gap plate assembly 18, one core 28 constituting the middle portion of the U-shaped portion has a rectangular cross section and is formed in a continuous substantially U shape.

  Each gap plate 30 is made of a non-magnetic material such as ceramics or resin into a predetermined shape. In the present embodiment, each gap plate 30 is formed in a thin plate shape having a rectangular cross-sectional shape. For example, the thickness of each gap plate 30 is the same. As shown in FIG. 4, the end faces in the thickness direction of the plurality of gap plates 30 are made larger than the end faces of the cores 24 (26, 28) with which the gap plates 30 are brought into contact, and all the outer peripheral edges 32 of the gap plates 30. Is positioned outside the outer peripheral edge 34 of the end face of the core 24 (26, 28) with which the gap plate 30 is brought into contact.

  Then, as shown in FIG. 3, a core gap plate assembly 18 constituted by joining a plurality of cores 24, 26, 28 and a gap plate 30 is installed in a mold (not shown), and a thermoplastic resin is injected. By molding, a U-shaped resin mold core 16 as shown in FIG. 2 is produced. In this state, for example, the end surfaces 20 of some cores 24 are formed on the inner surface of the mold during resin injection molding so that the end surfaces 20 of some cores 24 are exposed at the pair of end surfaces of the U-shaped resin mold core 16. Hit it. For this reason, of the plurality of cores 24, 26, 28 constituting the U-shaped resin mold core 16, some of the cores 24 are provided at one end of each, and are exposed to the outside without being covered with resin. It has the end surface 20 which is a partial exposure surface. Further, as shown in FIG. 5, the thickness direction of each projecting portion 36 (the left and right in FIG. 5) is a portion projecting outward from the outer periphery of the cores 24, 26, 28 at the outer periphery of each gap plate 30. (Direction) The resin constituting the bobbin 22 provided on both sides is continued at the outer portion of each protrusion 36.

  The resin constituting the bobbin 22 is a thermoplastic resin such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT). At the time of resin injection molding, after deforming at a high temperature of about 200 ° C. or higher, the core gap plate assembly 18 is injection insert molded with resin.

  In the present embodiment, as shown in FIG. 2, the core 24 is exposed to the outside at two portions on both ends of the U-shaped resin mold core 16, but the core is exposed to the outside at least at one portion. I just want to do it. A pair of U-shaped resin mold cores 16 each configured as described above has a pair of U-shaped resin mold cores that are exposed at the pair of end portions with the core 24 exposed to the outside via an intermediate gap plate made of a nonmagnetic material (not shown). The mold cores 16 are joined together to form the annular resin mold core 12 shown in FIG. Then, a pair of coils 14 are wound around a pair of I-shaped portions of the annular resin mold core 12 facing each other to constitute the reactor 10. Both ends of the pair of coils 14 can be used as a transformer element by connecting to another electric circuit (not shown) between the pair of coils 14, and by connecting one ends of the pair of coils 14, It can also be used as a single reactor.

  According to such a U-shaped resin mold core 16 and the reactor 10, when the U-shaped resin mold core 16 is taken out from the mold during the bobbin 22 molding, the resin shrinkage occurs when the temperature of the high-temperature resin drops to room temperature. Even if it occurs, the contraction force can be prevented from being applied to the entire resin. That is, as shown in FIG. 5, when the temperature of the resin drops from the high temperature during molding to room temperature when the bobbin 22 is molded, the resin contracts, and tensile stress in the direction indicated by the arrow in FIG. 5 acts on the resin. However, the protruding portions 36 of the gap plates 30 that protrude outward from the outer peripheral edges of the cores 24, 26, and 28 can prevent the tensile stress from reaching a wide range beyond the outer peripheral edge of the gap plate 30. In other words, the range in which the resin shrinks is within a narrow range sandwiched between two adjacent gap plates 30, or within a narrow range from the end surface 20 of the core 24 at both ends to the gap plate 30 near both ends, respectively. The amount of resin shrinkage can be reduced. For this reason, even if resin contraction occurs, the contraction force applied to the entire resin can be suppressed by the protruding portion 36 of the gap plate 30 protruding outward from the outer peripheral edges of the cores 24, 26, 28. As a result, the tensile stress applied to the end portion of the U-shaped resin mold core 16 can be reduced, the stress applied to the boundary between the end surface 20 of the core 24 and the resin can be reduced, and the surface of the core 24 is cracked. Can be effectively prevented, and the yield of the U-shaped resin mold core 16 can be improved. Therefore, a decrease in inductance of the reactor 10 configured by the U-shaped resin mold core 16 can be suppressed, and functions required of the reactor 10 as an electric component such as a transformer element can be effectively exhibited.

  In addition, among the plurality of cores 24, 26, and 28, some of the cores 24 have an end surface 20 that is provided at an end portion and is exposed to the outside. Therefore, unlike the present embodiment, when the configuration of the present embodiment in which at least some of the outer peripheral edges of the plurality of gap plates 30 are positioned outside the outer peripheral edges of the cores 24, 26, 28 is not adopted. In this case, due to the resin shrinkage when the high temperature resin at the time of molding the bobbin 22 is lowered to room temperature, stress is easily applied to the boundary portion between the end face 20 and the resin, and the surface of the core 24 is likely to be cracked. For this reason, the effect acquired by employ | adopting the structure of this Embodiment becomes more remarkable.

  FIGS. 6 to 8 show a core gap plate assembly 38 (FIG. 6) and a U-shaped resin mold core constituting a reactor of an example of a conventional example that has been conventionally considered for comparison with the present invention. 40 (FIGS. 7 and 8). FIG. 6 is a perspective view showing a core gap plate assembly before resin molding, which constitutes one U-shaped resin mold core constituting one example of a conventional reactor, and FIG. 7 is a conventional reactor. It is a figure corresponding to FIG. 5 which shows one U-shaped resin mold core which comprises one example of an example. FIG. 8 is a schematic perspective view showing how a crack is generated on the core surface due to resin shrinkage in one U-shaped resin mold core constituting one example of a conventional reactor.

  As shown in FIG. 6, in this conventional example, unlike the case of the present embodiment, the shape and area of the end face of the gap plate 30 are the same as the cores 24, 26, and 28 in contact with the gap plate 30. The outer peripheral edge of 30 is not projected outward from the outer peripheral edges of the cores 24, 26 and 28. As shown in FIGS. 7 and 8, some cores 24 have an end surface 20 that is provided at the end and is exposed to the outside without being covered with resin. For this reason, as shown in FIG. 7, when the U-shaped resin mold core 40 is taken out from the mold at the time of molding the resin bobbin 22, the resin shrinkage occurs when the temperature of the high temperature resin drops to room temperature. When it occurs, the contraction force extends over a wide range of resin as shown by the arrows in FIG. For this reason, the tensile stress applied to the end portion of the U-shaped resin mold core 40 increases, and the stress applied to the boundary between the end surface 20 of the core 24 and the resin increases. In this case, as shown in FIG. 8, there is a possibility that a crack 42 may occur on the surface of the core 24, which causes the yield of the U-shaped resin mold core 40 to deteriorate.

  In the case of the present embodiment, as described above, a part of the cores 24 is provided on the end portion and has the end surface 20 that is the end exposed surface exposed to the outside. Since the peripheral edge protrudes outward from the outer peripheral edges of the cores 24, 26, 28, it is possible to prevent such inconvenience, and the effect obtained by adopting the configuration of the present embodiment becomes more remarkable.

  The plurality of cores 24, 26, and 28 are made of a magnetic core obtained by combining powder particles of a metallic material, such as a dust core. Therefore, unlike the present embodiment, when the configuration of the present embodiment in which at least some of the outer peripheral edges of the plurality of gap plates 30 are positioned outside the outer peripheral edges of the cores 24, 26, 28 is not adopted. In this case, the surface of the core 24 is easily cracked due to the resin shrinkage when the high temperature resin at the time of molding is lowered to room temperature. For this reason, the effect acquired by employ | adopting the structure of this Embodiment becomes more remarkable.

  As shown in FIG. 5, in the present embodiment, the outer peripheral edge of each gap plate 30 does not reach the outer surface of the resin bobbin 22, and the outer peripheral edge portion of each gap plate 30 The resin provided on both sides in the thickness direction of each projecting portion 36, which is a portion projecting outward from the outer peripheral edge of the cores 24, 26, 28, is continued at the outer portion of each projecting portion 36. However, the present invention is not limited to such a configuration, and the resins that cover the outer sides of the cores 24, 26, and 28 are arranged so that the outer peripheral edge of each gap plate 30 is exposed to the outside from the resin bobbin. The gap plate 30 can be completely separated at the outer peripheral edge portion. In the case of such a configuration, for example, a high temperature resin is injected into the mold from a plurality of injection holes corresponding to the positions of the plurality of cores 24, 26, and 28 in a state where the core gap plate assembly is installed in the mold. Thus, a U-shaped resin mold core is formed. According to such a configuration, when a U-shaped resin mold core is taken out from a mold during resin bobbin molding, even if the resin shrinks when the temperature of the high temperature resin drops to room temperature, the shrinkage force The effect that can be effectively suppressed by the plurality of gap plates is added to the entire resin.

[Second Embodiment]
FIG. 9 is a diagram showing a gap plate constituting the U-shaped resin mold core according to the second embodiment of the present invention. FIG. 10 is a view corresponding to FIG. 4 showing the core gap plate assembly before resin molding, which constitutes the U-shaped resin mold core according to the second embodiment. FIG. 11 is a view corresponding to FIG. 5 and showing a U-shaped resin mold core according to the second embodiment.

In the present embodiment, each gap plate 30a is formed in a thin plate shape having a cross-shaped cross section. Further, as shown in FIG. 10, a plurality of cores 24, 26, and 28 (see FIG. 11 for 26 and 28) are joined via one gap plate 30a to form a core gap plate assembly 18a. Thus, each gap plate 30a protrudes outward from the linear portion 44, which is the core-side linear outer peripheral portion constituting the four positions of the outer peripheral edges of the cores 24, 26, 28, at four positions in the circumferential direction. A protrusion 46 is provided. Each protrusion 46 has a linear portion 48 which is a gap plate side linear outer peripheral portion parallel to the linear portion 44 at the tip. Then, the width W A1 of the linear portion 48 of each projection 46, a direction orthogonal to the 24, 26, 28 arrangement direction of the plurality of cores (lateral direction in FIG. 11) (the left-right direction in FIG. 10), each Dimensions and arrangement relationship of each part so that it has a size of 1/4 or more of the width W B1 of the linear part 44 constituting the outer peripheral edge of the cores 24, 26, 28 (W A1 ≧ ¼ × W B1 ). Is regulated.

In addition, the protrusion height H C1 of each protrusion 46 of each gap plate 30a from the linear portion 48 has a size of 0.4 mm or more (H C1 ≧ 0.4 mm). The placement relationship is regulated. Further, in the U-shaped resin mold core 16a, the resin provided on both sides in the thickness direction of each protrusion 46 included in each gap plate 30a is continued at the outer portion of the protrusion 46. Further, the minimum of the bobbin 22 that is the resin on the outside from the linear portion 48 of the gap plate 30a in the direction (vertical direction in FIG. 11) orthogonal to the arrangement direction of the cores 24, 26, and 28 (horizontal direction in FIG. 11). The thickness Dmin regulates the dimensions and arrangement relationship of each part so that it has a size of 1 mm or more (Dmin ≧ 1 mm).

According to such a U-shaped resin mold core 16a, the width W A1 of the linear portion 48 of the gap plate 30a in the direction perpendicular to the arrangement direction of the plurality of cores 24, 26, 28 is the cores 24, 26, The protrusion height H C1 of each protrusion 46 of each gap plate 30a from the linear part 44 has a size of 1/4 or more of the width W B1 of the 28 linear parts 44, and is 0.4 mm. It has the above size. For this reason, resin contraction can be suppressed by the gap plate 30a, and the occurrence of cracks on the surface of the core 24 can be more effectively suppressed.

  In addition, the resin provided on both sides in the thickness direction of each protrusion 46 included in each gap plate 30a is continued at the outer portion of the protrusion 46, and the direction perpendicular to the arrangement direction of the cores 24, 26, 28 is related to. The minimum thickness Dmin of the bobbin 22 that is the resin on the outside from the linear portion 44 of the gap plate 30a has a size of 1 mm or more. For this reason, the intensity | strength of a resin part can be improved more effectively. Since other configurations and operations are the same as those in the first embodiment, equivalent parts are denoted by the same reference numerals, and overlapping illustrations and descriptions are omitted.

In the first embodiment shown in FIG. 1 to FIG. 5, the outer peripheral edge portions of the gap plates 30 are provided on the outer peripheral edge portions of the gap plates 30 as in the present embodiment. The protrusion height H C2 (see FIG. 4) of each protrusion 36 protruding outward from the linear outer peripheral edge constituting the cores 24, 26, 28 has a size of 0.4 mm or more (see FIG. 4). (H C2 ≧ 0.4 mm) The dimensions and the arrangement relationship of each part can also be regulated. According to such a configuration, it is possible to suppress the resin shrinkage by the gap plate 30 and more effectively prevent the surface of the core 24 from being cracked. Further, as described with reference to FIG. 5, in the first embodiment, a direction (vertical direction in FIG. 5) perpendicular to the arrangement direction of cores 24, 26, 28 (horizontal direction in FIG. 5). ) Regarding the dimensions and arrangement of each part so that the minimum thickness Dmin ′ of the bobbin 22 that is the resin on the outside from the linear outer peripheral edge of the gap plate 30 has a size of 1 mm or more (Dmin ≧ 1 mm). Can also be regulated. According to such a configuration, the strength of the resin portion can be more effectively improved.

[Third Embodiment]
FIG. 12 is a view corresponding to FIG. 4 showing the core gap plate assembly before resin molding, which constitutes the U-shaped resin mold core according to the third embodiment of the present invention. In the case of the present embodiment, each gap plate 30b is formed in a thin plate shape having a cross-sectional shape in which middle portions in the length direction of four sides constituting a rectangle are recessed in a rectangular shape. And in the state which joined the some core 24 via the gap board 30b one by one, and comprised the core gap board assembly 18b, each gap board 30b is the outside of a core in four places which comprise a corner | angular part. An L-shaped projecting portion 50 projecting outward from the linear portion 44 that is the core-side linear outer peripheral portion constituting the four positions of the peripheral edge is provided. In the case of the present embodiment using the gap plate 30b having such a shape, the U-shaped resin is formed from the mold when the resin bobbin 22 (see FIG. 5 and the like) is molded, as in the above embodiments. When the mold core is taken out, even if the resin shrinks when the high temperature resin drops to room temperature, the shrinkage force is applied to the entire resin by the gap plate 30b protruding outward from the outer peripheral edge of the core 24. Can be suppressed. Other configurations and operations are the same as those of the first embodiment shown in FIGS. 1 to 5 or the second embodiment shown in FIGS. Are denoted by the same reference numerals, and overlapping illustration and description are omitted.

  The shapes of the gap plates 30, 30 a, 30 b and the cores 24, 26, 28 are not limited to those similar to those in the above embodiments. FIG. 13 is a view corresponding to FIG. 4 showing a core gap plate assembly before resin molding, which constitutes another three example U-shaped resin mold core according to the embodiment of the present invention. In a first example of another example shown in FIG. 13A, the gap plate 30c is formed in a thin plate shape with a circular cross section. And in the state which joined the some core 24 via the gap board 30c one by one, and comprised the core gap board assembly 18c, the circumferential direction 4 location part of the outer peripheral part of the gap board 30c is rectangular cross-section. It protrudes outward from the four portions of the outer peripheral edge of the core 24.

  In the second example of another example shown in FIG. 13B, the core 52 is formed in an I-shape or U-shape having a circular cross section, and the gap plate 30d is formed in a thin plate shape having a circular cross section larger than the cross sectional shape of the core 52. The end face of the gap plate 30 d that is brought into contact with the core 52 is also formed in a larger circle than the core 52. And in the state which joined the several core 52 via the gap board 30d one by one and comprised the core gap board assembly 18d, the outer peripheral edge part of the gap board 30d is the outer surface of the end face of the core 52 over the perimeter. It protrudes outward from the periphery.

  In the third example of another example shown in FIG. 13C, the core 52 is formed in an I-shape or U-shape having a circular cross section, and the gap plate 30 has a rectangular cross section, as in the first embodiment. It is formed in a thin plate shape. And in the state which joined the some core 52 via the gap board 30 one by one and comprised the core gap board assembly 18e, the outer peripheral edge part of the gap board 30 is outside the end surface of the core 52 over the perimeter. It protrudes outward from the periphery. In the case of three other examples shown in FIGS. 13 (a), 13 (b), and 13 (c), the U-shaped resin mold core was taken out from the mold when the resin bobbin 22 (see FIG. 5 and the like) was molded. In this case, even if resin shrinkage occurs when the temperature of the high-temperature resin drops to room temperature, the shrinkage force is applied to the entire resin. The gap plates 30c, 30d, 30e projecting outward from the outer peripheral edges of the cores 24, 52. Can be suppressed.

[Fourth Embodiment]
FIG. 14: is a perspective view which shows the I-shaped resin mold core which is the resin mold core of the 4th Embodiment of this invention in the state before a resin mold (a), and after a resin mold (b). . As shown in FIG. 14B, in the present embodiment, a plurality of rectangular rectangular cores 24, a plurality of rectangular rectangular cross-section gap plates 30, and a resin bobbin 22, A letter-shaped resin mold core 54 is formed. That is, as shown in FIG. 14A, a plurality of cores 24 made of a magnetic material and a plurality of gap plates 30 made of a non-magnetic material are arranged alternately adjacent to each other in a straight line, and joined together. Thus, an I-shaped core gap plate assembly 56 is formed. 14A, the thickness direction end faces of the plurality of gap plates 30 are made larger than the end face of the core 24 with which the gap plates 30 are brought into contact, and the entire outer peripheral edge of each gap plate 30 is formed. The core 24 is positioned outside the outer peripheral edge of the end face. Then, the core gap plate assembly 56 is placed in a mold (not shown), and a thermoplastic resin is injection-molded to make an I-shaped resin mold core 54 shown in FIG. 14B. In this state, the end faces 20 of the core 24 are exposed at both end faces of the I-shaped resin mold core 54. That is, of the plurality of cores 24 constituting the I-shaped resin mold core 54, the two cores 24 constituting both ends of the I-shaped resin mold core 54 are provided at one end portions and covered with the resin. And an end face 20 which is an end exposed face exposed to the outside. In addition, the resin provided on both sides in the thickness direction of each protrusion 36, which is a part protruding outward from the outer periphery of the core 24, at the outer peripheral edge of each gap plate 30, is the outer part of each protrusion 36. It is continuous. Further, the reactor is configured by winding the coil 14 (see FIG. 1) around the outside of the I-shaped resin mold core 54.

  In the case of this embodiment as well, as in each of the above-described embodiments, when the I-shaped resin mold core 54 is taken out from the mold at the time of molding the resin bobbin 22, the high-temperature resin reaches room temperature. Even if resin shrinkage occurs when the temperature is lowered, the shrinkage force applied to the entire resin can be suppressed by the gap plate 30 protruding outward from the outer peripheral edge of the core 24. Other configurations and operations are the same as those of the first embodiment shown in FIGS. 1 to 5 described above, and thus redundant description is omitted.

[Fifth Embodiment]
FIG. 15: is a perspective view which shows the I-shaped resin mold core which is the resin mold core of the 5th Embodiment of this invention in the state before a resin mold (a), and after a resin mold (b). . As shown in FIG. 15A, in the case of the present embodiment, in the fourth embodiment shown in FIG. 14, the core 52 is formed in a short column shape with a circular cross section, and the gap plate 30d is formed. It is formed in a thin plate shape with a circular cross section. Further, in a state where the plurality of cores 52 are joined through the gap plates 30d one by one to form the core gap plate assembly 56a, the outer peripheral edge portion of the gap plate 30d is placed outside the end face of the core 52 over the entire circumference. It protrudes outward from the periphery. Moreover, the I-shaped resin mold core 54a shown in FIG.15 (b) is comprised by carrying out injection insert molding of the core gap board assembly 56a with resin. In the case of this embodiment as well, when the I-shaped resin mold core 54a is taken out from the mold during the molding of the resin bobbin 22, the resin shrinkage occurs when the temperature of the high temperature resin drops to room temperature. However, it is possible to suppress the contraction force from being applied to the entire resin by the gap plate 30d protruding outward from the outer peripheral edge of the core 52. Other configurations and operations are the same as those of the first embodiment shown in FIGS. 1 to 5 or the fourth embodiment shown in FIG.

[Sixth Embodiment]
FIG. 16: is a perspective view which shows the I-shaped resin mold core which is the resin mold core of the 6th Embodiment of this invention in the state before a resin mold (a), and after a resin mold (b). . As shown in FIG. 16A, in the present embodiment, the number of cores 24 and gap plates 30 is made larger than in the case of the fourth embodiment shown in FIG. The joined body 56b is configured. Further, in the case of the fourth embodiment shown in FIG. 14, the entire length of the I-shaped resin mold core 54b (FIG. 16B) constituted by the core gap plate assembly 56b and the resin bobbin 22 is shown. Is bigger than. Other configurations and operations are the same as those in the fourth embodiment described above, and a duplicate description is omitted.

[Seventh Embodiment of the Invention]
FIG. 17: is a perspective view which shows the I-shaped resin mold core which is the resin mold core of the 7th Embodiment of this invention in the state before resin molding. In the case of the present embodiment, in the sixth embodiment shown in FIG. 16 described above, the plurality of gap plates are two types of gap plates 30 and 58 having different sizes, and the large gap plate 30; The core gap plate assembly 56c is configured by alternately arranging the small gap plates 58 via the cores 24 one by one and joining them linearly. The cross-sectional area of the small gap plate 58 is substantially the same as the cross-sectional area of the core 24, and the sizes of the end surfaces in contact with the gap plate 58 and the core 24 are also substantially the same. In the case of such a configuration, the I-shaped resin mold core was taken out from the mold when the resin bobbin 22 (see FIG. 16) was molded, as compared with the case of the sixth embodiment shown in FIG. In this case, the effect of suppressing the entire resin shrinkage caused when the temperature of the high-temperature resin is lowered to room temperature by the gap plate 30 protruding outward from the outer peripheral edge of the core 24 becomes low. However, in the present embodiment, the material required for the entire gap plates 30 and 58 can be reduced as compared with the case of the sixth embodiment. Other configurations and operations are the same as those of the first embodiment shown in FIGS. 1 to 5 or the sixth embodiment shown in FIG. To do.

[Eighth Embodiment]
18A and 18B show a gap plate constituting a U-shaped resin mold core, which is a resin mold core according to an eighth embodiment of the present invention. FIG. 18A is a front view, and FIG. 18B is a side view. It is a figure. FIG. 19 is a view corresponding to the AA cross section of FIG. 4 showing the U-shaped resin mold core of the eighth embodiment. In the case of this embodiment, in the first embodiment shown in FIGS. 1 to 5, the gap plate 60 is formed with a hole 62 having a rectangular cross section penetrating in the axial direction at the center. ing. A plurality of cores 24, 26, and 28 (see FIG. 3 for 28) are joined to each other via the gap plate 60, and the outer peripheral edge portion of the gap plate 60 in a state in which the core gap plate assembly 18f is configured. Is protruded outward from the outer peripheral edge of the end face of the cores 24, 26, 28 over the entire circumference. Further, the core gap plate assembly 18f is injection-insert molded with a resin to form a U-shaped resin mold core 16b as shown in FIG. 18B. In this state, a space 64 is formed inside the hole 62 of each gap plate 60.

  According to this embodiment, the entire volume of the gap plate 60 is reduced, and the material of the gap plate 60 can be reduced. For this reason, the cost of the U-shaped resin mold core 16b can be reduced. Other configurations and operations are the same as those of the first embodiment shown in FIGS. 1 to 5 described above, and thus redundant description is omitted. The gap plate 60 having the hole 62 is not limited to the U-shaped resin mold core 16b. For example, the I-shaped resin mold core of the fourth to seventh embodiments shown in FIGS. It can also be used as a gap plate for constituting 54, 54a, 54b.

  FIG. 20 is a diagram showing another two examples of gap plates constituting the U-shaped resin mold core 16b of the eighth embodiment. First, in the case of the gap plate 60a of another first example shown in FIG. 20 (a), the gap plate 60a is recessed in an arc shape inwardly at the corner of the outer peripheral edge of the gap plate 60a and the corner of the hole 62a. The curved parts 66 and 68 formed so that it may be formed are formed. In the case of the gap plate 60b of another second example shown in FIG. 20 (b), the gap plate 60b is formed in a circular cross section with a circular hole 62b formed inside. Even when the gap plates 60a and 60b of the other two examples are used, a plurality of cores 24, 26 and 28 (see FIG. 3) are joined via the gap plates 60a and 60b one by one. In the state where the plate assembly is configured, the outer peripheral edge portions of the gap plates 60a and 60b are projected outward from the outer peripheral edge of the end surfaces of the cores 24, 26 and 28 over the entire periphery. Thus, in the present invention, the shape of the gap plate is not particularly limited, and various shapes can be adopted.

[Ninth Embodiment]
FIG. 21 is a cross-sectional view of a gap plate portion showing a core gap plate assembly before resin molding that constitutes a U-shaped resin mold core, which is a resin mold core according to a ninth embodiment of the present invention. FIG. 22 is a view corresponding to the BB cross section of FIG. 21, showing the U-shaped resin mold core of the ninth embodiment in a state after resin molding. The U-shaped resin mold core of the present embodiment is configured by resin molding the core gap plate assembly 70 shown in FIG. The core gap plate assembly 70 includes a plurality of gap plates 60a having the same shape as that of the first example of another example shown in FIG. 20A and a plurality of inner gap plates 72. A plurality of cores 24, 26, and 28 (see FIG. 3 for 28) are joined via one gap plate 60 a, and the core gap plate assembly 70 is configured, and inside each gap plate 60 a, The inner gap plate 72 is disposed through the gap, and the inner gap plate 72 is joined to the end faces of the cores 24, 26, 28 on both sides. The inner gap plate 72 is formed in a thin plate shape with a substantially rectangular cross section.

  Further, in the state in which the core gap plate assembly 70 is configured, the four circumferential positions of the outer peripheral edge of the gap plate 60a are protruded outward from the outer peripheral edges of the end surfaces of the cores 24, 26, and 28 with which the gap plate 60a contacts. ing. And the U-shaped resin mold core 16c is comprised as shown in FIG. 22 by carrying out injection insert molding of the core gap board assembly 70 with resin. In this state, an annular space 74 is formed between the inner peripheral surface of the hole 62 a of each gap plate 60 a and the outer peripheral surface of the inner gap plate 72.

  According to the present embodiment, it is possible to more effectively suppress the variation in the shape of the entire U-shaped resin mold core 16c while reducing the material of the gap plate 60a and the entire inner gap plate 72. Even when the end surfaces of the cores 24, 26, and 28 facing the gap plate 60a are not flat surfaces having different heights in the thickness direction between the central portion and the end portions, the gap plate 60a and the inner gap plate 72 By appropriately changing the thickness, it is possible to more effectively suppress variation in the shape of the entire U-shaped resin mold core 16c. Other configurations and operations are the same as those of the first embodiment shown in FIGS. 1 to 5 or the first example of another example of the gap plate 60a shown in FIG. 20 (a). Therefore, the same parts are denoted by the same reference numerals, and redundant description is omitted. In this embodiment, the case where the gap plate 60a and the inner gap plate 72 constitute the U-shaped resin mold core 16c has been described. However, the resin mold core can be formed in various shapes such as an I-shape.

[Tenth Embodiment]
FIG. 23 is a view corresponding to the BB cross section of FIG. 21 showing a U-shaped resin mold core, which is a resin mold core according to the tenth embodiment of the present invention, in a state after resin molding. FIG. 24 is a view of the gap plate constituting the U-shaped resin mold core of the eleventh embodiment, taken from the left-right direction of FIG. In the case of the present embodiment, in the ninth embodiment shown in FIGS. 21 to 22 described above, the outer side of the outer peripheral edge of the cores 24, 26, 28 (28 refer to FIG. 3) of the gap plate 60a. Guide protrusions 76, which are guide parts protruding in the thickness direction, are provided on both side surfaces in the thickness direction (left and right direction in FIG. 23) of at least some of the plurality of protrusions protruding in the direction. The ends of the cores 24, 26, and 28 are inserted while being guided at least inside the two guide protrusions 76 facing each other. Each guide protrusion 76 suppresses misalignment of the cores 24, 26, and 28 with respect to the gap plate 60a.

  Further, the inner gap plate 72a disposed inside each gap plate 60a includes small protrusions 78 provided so as to protrude in the thickness direction at a plurality of positions on both side surfaces in the thickness direction. The tip of this is abutted against the end surfaces of the cores 24, 26 and 28. The core gap plate assembly 70a is configured by joining the plurality of cores 24, 26, and 28 via one gap plate 60a and an inner gap plate 72a disposed on the inside thereof. And the U-shaped resin mold core 16d is comprised by carrying out injection insert molding of the core gap board assembly 70a with resin.

  In this embodiment, each inner gap plate 72a includes a plurality of small protrusions 78 provided on both side surfaces facing the cores 24, 26, and 28 so as to protrude in the thickness direction. For example, even when the end surfaces of the cores 24, 26 and 28 facing the inner gap plates 72a are not flat, the area of the contact portion between the inner gap plates 72a and the end surfaces of the cores 24, 26 and 28 can be reduced. The gap plate 72a can be hardly tilted with respect to the cores 24, 26, and 28. For this reason, it can suppress more effectively that the shape of the whole U-shaped resin mold core 16d varies.

  In addition, each gap plate 60a is provided on both sides in the thickness direction of the protruding portion that protrudes outward from the outer peripheral edges of the cores 24, 26, 28, and suppresses displacement of the cores 24, 26, 28 with respect to the gap plate 60a. And a guide projection 76 for performing the above operation. Therefore, before the resin molding of the U-shaped resin mold core 16d, the two cores 24, 26, 28 and the gap plate 60a are kept in a predetermined positional relationship, and the two cores 24, 26, respectively. , 28 can be combined more easily so as to dispose the gap plate 60a between them. Since other configurations and operations are the same as those of the ninth embodiment shown in FIGS. 21 to 22 described above, the same parts are denoted by the same reference numerals, and redundant description is omitted. In the present embodiment, the case where the gap plate 60a and the inner gap plate 72a constitute the U-shaped resin mold core 16d has been described. However, the resin mold core can be formed in various shapes such as an I-shape.

  In each of the above embodiments, the case where the reactor is configured by winding the coil 14 (FIG. 1) around the U-shaped resin mold core or the I-shaped resin mold core has been described. It can also be provided inside the U-shaped resin mold core or the I-shaped resin mold core. For example, a coil can be provided inside a resin bobbin.

  10 reactor, 12 annular resin mold core, 14 coil, 16, 16a, 16b, 16c, 16d U-shaped resin mold core, 18, 18a, 18b, 18c, 18d, 18e, 18f core gap plate assembly, 20 end face, 22 Bobbin, 24, 26, 28 Core, 30, 30a, 30b, 30c, 30d Gap plate, 32, 34 Outer peripheral edge, 36 Projection, 38 Core gap plate assembly, 40 U-shaped resin mold core, 42 Crack, 44 Straight line 46, projecting portion, 48 linear portion, 50 projecting portion, 52 core, 54, 54a, 54b I-shaped resin mold core, 56, 56a, 56b, 56c core gap plate assembly, 58 gap plate, 60, 60a , 60b Gap plate, 62, 62a, 62b Hole, 64 Space, 66, 68 Curved , 70, 70a core gap plates bonded body, 72, 72a inner gap plates, 74 space, 76 guide projection, 78 small protuberances.

Claims (9)

  1. A resin mold core comprising a gap plate made of a non-magnetic material disposed between a plurality of cores made of a magnetic material, and formed by molding the plurality of cores and the gap plate with resin from the outside,
    The gap plate is formed by positioning at least a part of the outer peripheral edge outside the outer peripheral edge of the core that contacts the gap plate, and has a protrusion for suppressing resin shrinkage covered with the resin. Resin mold core.
  2. In the resin mold core according to claim 1,
    Among the plurality of cores, at least a part of the cores is provided at an end portion, and has an end exposed surface exposed to the outside by being not covered with resin.
  3. In the resin mold core according to claim 1 or 2 ,
    The protrusion part of a gap board is made to protrude over the perimeter rather than the outer periphery of the core which contacts a gap board, The resin mold core characterized by the above-mentioned.
  4. In the resin mold core according to any one of claims 1 to 3 ,
    The plurality of cores are made of a magnetic core obtained by combining powder particles of a metal-based material.
  5. In the resin mold core according to any one of claims 1 to 4 ,
    The gap plate has a resin mold core in which a hole penetrating in the axial direction is formed in a central portion.
  6. In the resin mold core according to any one of claims 1 to 5 ,
    The resin mold core, wherein the gap plate has a circular cross section.
  7. In the resin mold core according to claim 5 or 6 ,
    A resin mold core comprising an inner gap plate disposed inside a gap plate through a gap.
  8. The resin mold core according to any one of claims 1 to 7 ,
    And a coil wound around the resin mold core.
  9. An annular resin mold core according to any one of claims 1 to 7 , which is constituted by joining a pair of resin mold cores each formed in a U shape,
    A reactor comprising a coil wound around a pair of I-shaped portions on both sides of an annular resin mold core.
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