JP5899926B2 - Reactor and its manufacturing method - Google Patents

Description

  The present invention relates to a reactor and a manufacturing method thereof. A reactor is a passive element using a coil, and is sometimes called an “inductor”.

  In recent years, hybrid vehicles and electric vehicles have been put into practical use and are spreading. Since a hybrid vehicle or an electric vehicle uses a motor as a drive source, the electric circuit for the motor is often provided with a reactor. The reactor body is formed by winding a coil (coil) around a bobbin having a metal core inside. Ferrite is often used for the core. Bobbins are often made of resin.

  As a kind of reactor, there is a reactor having a core in which a pair of U-shaped cores and at least one I-shaped core are connected in a ring shape. Patent Documents 1 to 3 disclose a reactor having an annular core, and these documents all divide the annular core. By dividing the annular core, the ease of manufacturing is enhanced.

JP 2007-180140 A JP 2008-078219 A JP 2011-086801 A

  The present specification relates to a reactor in which an annular core is divided, and provides a technique for further improving the ease of assembly.

  Many reactors are provided with a bobbin (resin molding part) that surrounds a metal core and winds a coil. The technology disclosed in the present specification devise the shape of the resin molding part and improve the assemblability of the divided cores.

The technology disclosed in this specification can be embodied in a reactor, in part. The reactor includes a core configured by connecting a pair of U-shaped cores and at least one I-shaped core in a ring shape, and a resin molded portion covering the periphery of the end of the U-shaped core. And the cylindrical guide part which positions an I-shaped core is provided in the resin molding part so that the end surface of a U-shaped core may be opposed. By fitting the I-shaped core 3 into the guide portion 5 and combining the pair of U-shaped resin molded portions 4a and 4b, an annular resin molded portion is completed. By providing the resin molded portion with the guide portion, the ease of assembling the I-shaped core is improved.

  In the above reactor, it is preferable that the guide portion has a cylindrical shape that houses the I-shaped core therein. By storing the I-shaped core in the cylindrical guide portion, the position of the I-shaped core can be easily determined. That is, the assemblability is further improved.

  The reactor disclosed in this specification may further include a resin molded portion having the same shape for each of the pair of U-shaped cores. In many cases, the resin molding part is formed by injection molding around a core by placing a U-shaped core in a mold. If the resin molding parts molded with respect to each of the pair of U-shaped cores have the same shape, the pair of resin molding parts can be manufactured with one mold.

  In the reactor disclosed in this specification, each of the pair of resin molding parts has a guide part, and the pair of U-shaped cores and the I-shaped cores are assembled in an annular shape with the I-shaped cores positioned. It is preferable that the guide portions are configured to come into contact with each other. The guide part is useful not only for positioning the I-shaped core but also for mutual positioning of the pair of resin molding parts.

Said resin molding part has the through-hole which connects the space between the U-shaped core and the positioned I-shaped core, and the exterior in the side surface of a guide part . A space may be provided between the U-shaped core and the I-shaped core. In that case, the resin can be poured into the space later through the through hole.

This specification also provides the manufacturing method of an above-described reactor. In the manufacturing method, a resin molding part is molded so as to cover the periphery of at least one of the U-shaped cores, and an I-shaped core is sandwiched between a pair of U-shaped cores in a ring shape. An assembly process for assembling the core is provided. The molding process is performed before the assembly process. In the molding step, a cylindrical guide portion for positioning the I-shaped core is molded at the end of the resin molded portion so as to face the end surface of the U-shaped core. This manufacturing method avoids the generation of burrs due to dimensional variation of the I-shaped core compared to the case where the resin-molded part that puts the U-shaped core and the I-shaped core into the mold and fixes them is injection molded. Has the advantage of That is, there is a dimensional variation in the core, and when the resin is injection-molded with both the U-shaped core and the I-shaped core in the mold, if the dimension of the I-shaped core is small, there is an excess in the mold. A space is created, and the space is filled with resin to form burrs. Generation of burrs can be avoided by a method of assembling the I-shaped core after injection molding of the resin molded portion.

  The guide part is good to be shape | molded by the cylinder shape which accommodates an I-shaped core inside. Moreover, it is good for the resin molding part of the same shape to be provided with respect to each of a pair of U-shaped core. Alternatively, each of the pair of resin molded portions has a guide portion, and when the pair of U-shaped core and the I-shaped core are assembled in an annular shape with the I-shaped core positioned, the respective guide portions are May be configured to contact each other.

Moreover, the resin molding part has a through hole in the side surface of the guide part that connects the space between the U-shaped core and the positioned I-shaped core and the outside, and the I-shaped core is formed on the resin molding part. After the assembly, a secondary molding step of filling the space with resin is further provided. The space between the end face of the U-shaped core and the I-shaped core can be easily filled with resin.

It is a perspective view of a reactor. It is a perspective view of the divided | segmented core. It is an exploded view of a resin molding part. It is sectional drawing of a core and a resin molding part. It is sectional drawing of a reactor. The exploded view of the resin molding part in 2nd Example. It is a perspective view of the assembled resin molding part. It is sectional drawing of the core and resin molding part in the reactor of 3rd Example. It is sectional drawing of the reactor of 3rd Example.

  FIG. 1 is a perspective view of a reactor 10 according to the first embodiment. The reactor 10 is obtained by winding a coil 8 around a resin molded portion 4 (4a, 4b) that wraps a metal core. The resin molding part 4 is comprised by the two coil winding parts substantially parallel, and the curved part which connects the edge parts of two coil winding parts, and the whole is cyclic | annular. The coil 8 is wound around the two coil winding portions. Although the coil 8 is wound around two places of the resin molding part, it is electrically connected to one coil, so that it is electrically one coil. The reactor 10 is used for an inverter and a voltage converter of an electric vehicle, for example.

  As shown in FIG. 2, the core includes a pair of U-shaped cores 2 a and 2 b and two I-shaped cores 3. The pair of U-shaped cores 2a and 2b are arranged so that the end faces face each other, and the I-shaped core 3 is interposed between the end face of one U-shaped core 2a and the end face of the other U-shaped core 2b. Are arranged, and the core is annular as a whole. A gap plate 7 is disposed between the U-shaped core 2 a and the I-shaped core 3 and between the U-shaped core 2 b and the I-shaped core 3. The gap plate 7 is made of ceramic or the like.

  As shown in FIG. 3, the U-shaped cores 2a and 2b, the I-shaped core 3 and the gap plate 7 are covered with resin molded portions 4a and 4b. The resin molding part 4a (4b) is molded by placing a U-shaped core 2a (2b) in a mold and injecting resin around the end surface of the U-shaped core 2a (2b). That is, the resin molded portion 4a (4b) is also formed in a U shape. Only the end face of the U-shaped core 2a (2b) is exposed, and the others are covered with resin. A guide portion 5 for positioning the I-shaped core 3 is formed at the end of the U-shaped resin molded portion 4a (4b). The guide part 5 is formed in a cylindrical shape so as to extend in parallel from both ends of the U-shaped core 2a (2b). A coil is wound around the guide portion 5. A notch 21 is formed on the end surface of the guide portion 5.

  FIG. 4 is a cross-sectional view of the core and the resin molding part in the XY plane of the coordinate system in the exploded view of FIG. FIG. 5 is a cross-sectional view of reactor 10 in the YX plane of FIG. 4 and 5 show a cross section crossing the notch 21. FIG. One half of the I-shaped core 3 is accommodated in the cylinder of the guide portion 5 of the resin molded portion 4a with the gap plate 7 interposed therebetween. When the other half of the I-shaped core 3 is fitted so as to cover the guide portion 5 of the other resin molded portion 4b with the other gap plate 7 in between, a pair of U-shaped cores 2a and 2b, The core 3 has an annular arrangement with the gap plate 7 in between (see FIG. 5).

  When the pair of resin molded portions 4a and 4b are combined with the I-shaped core 3 interposed therebetween, the end surfaces of the guide portions 5 of the pair of resin molded portions 4a and 4b come into contact with each other. A pair of resin molding parts 4a and 4b are joined by applying an adhesive to the end surfaces of the guide part 5 and the I-shaped core 3 and combining the pair of resin molding parts 4a and 4b with the gap plate 7 therebetween. Is done. The coil 8 is formed in a coil shape in advance, and is passed through the end portions of the U-shaped resin molded portions 4a and 4b prior to combining the pair of resin molded portions 4a and 4b.

  As described above, in the reactor 10 of the first embodiment, the cylindrical guide portion 5 is formed at the end of the U-shaped resin molded portion 4a (4b) in which the U-shaped core 2a (2b) is embedded. The I-shaped core 3 is fitted into the guide portion 5 and positioned. The I-shaped core 3 is positioned so that its end surface faces the end surface of the U-shaped core 2a (2b). The I-shaped core 3 is fitted after molding a resin molded portion 4a (4b) that covers the U-shaped core 2a (2b) except for its end face. In the reactor 10 described above, the I-shaped core 3 can be easily incorporated. In addition, the notch 21 formed in the end surface of the guide part 5 becomes a through-hole which connects the inside and outside of a resin molding part, after joining a pair of resin molding parts 4a and 4b. Resin or the like is filled when a gap remains inside through the through hole. That is, the notch 21 is provided in order to fill a gap remaining inside after joining a pair of resin molded portions with resin or the like.

  A reactor 10a according to the second embodiment will be described with reference to FIGS. In the figure, the coil is not shown. FIG. 6 is a perspective view of the resin molded portions 14a and 14b and the cores 2a, 2b, and 3 of the reactor 10a according to the second embodiment. In this reactor 10a, six I-shaped cores 3 are used. Three I-shaped cores 3 are arranged in a row with respect to the respective end faces of the pair of U-shaped cores 2a and 2b. The gap plate 7 is disposed between the adjacent I-shaped cores 3 and between the I-shaped core 3 and the U-shaped core 2a (2b). Each of the pair of resin molding portions 14a and 14b includes U-shaped guide portions 15a and 15b. The U-shaped groove (guide portion 15a) of one resin molded portion 14a and the U-shaped groove (guide portion 15b) of the other resin molded portion 14b corresponding to this are complementary. A cylinder is formed (see FIG. 7). Three I-shaped cores 3 are accommodated inside the cylinder with the gap plate 7 interposed therebetween. In the reactor 10a of the second embodiment, the coil is formed in a coil shape in advance, and is passed through the end portions of the resin molded portions 4a and 4b prior to combining the pair of resin molded portions 14a and 14b. . Notches 21 are provided on the end surfaces of the guide portions 15a and 15b. After joining the pair of resin molded portions 14a and 14b, the notches 21 serve as holes that communicate the internal space containing the core with the outside ( (See FIG. 7). When a gap remains inside the joined resin molded portions 14a and 14b, resin or the like is filled from the notch 21.

  A reactor 10b according to a third embodiment will be described with reference to FIGS. 8 and 9, the coil is not shown. FIG. 8 is a cross-sectional view of the resin molding portions 24a and 24b and the cores (U-shaped cores 2a and 2b and six I-shaped cores 3) of the reactor 10b according to the third embodiment. The reactor 10b of the third embodiment is generally the same shape as the reactor 10 of the first embodiment, but differs in that the through hole 22 is provided on the side surface of the guide portion 5 of the resin molded portion 24a (24b). Similar to the notch 21, the through hole 22 is provided to fill the resin or the like when a gap remains inside after the resin molded portions 24a and 24b are joined. In the reactor 10b of the third embodiment, after the pair of resin molding portions 24a and 24b are combined, the resin remaining in the resin molding portion is filled through the through hole 22 and the notch 21 as secondary molding. . By filling the resin by secondary molding, it is possible to prevent a gap from remaining in the resin molded portion. Even if the size of the I-shaped core 3 varies, the reactor 10b according to the third embodiment fills the I-shaped core 3 by filling the resin as the secondary molding after joining the resin molded portions 24a and 24b. There is an advantage that it can be firmly fixed.

  Points to be noted regarding the technology of the embodiment will be described. As shown in FIG. 3, in the resin molding portions 4 a and 4 b of the first embodiment, four notches 21 are provided in one guide portion 5. As shown in FIG. 6, in the resin molded portions 14a and 14b of the second embodiment, notches 21 are provided in the upper and lower stages of the U-shaped groove-shaped guide portions 15a and 15b, respectively. The location and number of notches are not limited to the embodiments. For example, only one notch may be provided in one guide portion. Alternatively, in FIG. 3, two notches are provided on one surface of the guide portion 5, but only one notch may be provided on one surface. Furthermore, a notch is not provided in the surface (inner side surface) facing the other guide part in the parallel extending guide part, but a notch may be provided only in the outer side surface.

  Specific examples of the present invention have been described in detail above, but these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes of the specific examples illustrated above. The technical elements described in this specification or the drawings exhibit technical usefulness alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technology illustrated in the present specification or the drawings achieves a plurality of objects at the same time, and has technical utility by achieving one of the objects.

2a, 2b: U-shaped core 3: I-shaped core 3a: steps 4a, 4b, 14a, 14b, 24a, 24b: resin molded parts 5, 15a, 15b: guide part 7: gap plate 8: coil 10, 10a, 10b: Reactor 21: Through hole 22: Space

Claims (8)

A core constituted by a pair of U-shaped cores and at least one I-shaped core connected in a ring;
A resin molded portion covering the U-shaped core;
With
The resin molding part, the and the cylindrical guide portion for positioning the I-shaped core is provided so as to face the end faces of the U-shaped core,
The said resin molding part has the through-hole which connects the space between the said U-shaped core and the said I-shaped core positioned, and the exterior in the side surface of the said guide part, The reactor characterized by the above-mentioned . The guide portion, reactor according to claim 1, characterized in that the cylindrical fit the I-shaped core therein. The reactor according to claim 1 or 2, wherein a resin molded portion having the same shape is attached to each of the pair of U-shaped cores. Each of the pair of the resin molded portion has a guide portion, the I-shaped core and said pair of U-shaped cores in a state of being positioned with said I-shaped cores of people husband when assembled in an annular guide portion The reactor according to claim 3, wherein the abutments are in contact with each other. A resin molding part is formed in a core in which a pair of U-shaped cores and at least one I-shaped core are annularly connected, and a method of manufacturing a reactor in which a coil is wound around the resin molding part,
A molding step of molding the molded resin portion so as to cover the periphery of the end portion of at least one of the U-shaped core,
Equipped with, an assembly process for assembling a core connecting to the annular across the I-shaped core between the pair of U-shaped core,
It said forming step is carried out prior to the assembly process,
Wherein in the molding step, the the end of the molded resin portion, forming said cylindrical guide portion for positioning said I-shaped cores so as to face the end faces of the U-shaped core,
The resin molded portion has a through hole for connecting the space and the outside between the positioned U-shaped core the I-shaped core on a side surface of the guide portion, the I-shaped core the A reactor manufacturing method, further comprising a secondary molding step of filling the space with a resin after the resin molding part is assembled. The guide portion, the manufacturing method of the reactor according to claim 5, characterized in that it is formed into a cylindrical shape to fit the I-shaped core therein. The method for manufacturing a reactor according to claim 5 or 6, wherein a resin molded portion having the same shape is formed for each of the pair of U-shaped cores. Each of the pair of the resin molded portion has a guide portion, the I-shaped core and said pair of U-shaped cores in a state of being positioned with said I-shaped cores of people husband when assembled in an annular guide portion The method for manufacturing a reactor according to claim 7, wherein the abutments are in contact with each other.

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