WO2016208441A1 - Reactor and method for manufacturing reactor - Google Patents

Abstract

Provided are a reactor having excellent manufacturability and heat dissipation, and a method for manufacturing the same. The reactor is provided with a coil and a magnetic core disposed on the inside and outside of the coil and forming a closed magnetic path, wherein the magnetic core is an integrally molded article configured of a composite material including soft magnetic powder and resin, and the coil is provided with an exposed region in which at least a part of an outer peripheral surface of the coil is exposed and not covered by the magnetic core.

Description

Reactor and reactor manufacturing method

The present invention relates to a reactor used for a component part of a power conversion device such as an in-vehicle DC-DC converter mounted on a vehicle such as a hybrid vehicle, and a manufacturing method thereof. In particular, the present invention relates to a reactor that is excellent in manufacturability and heat dissipation.

Reactor is one of the circuit components that perform voltage step-up and step-down operations. Patent Document 1 discloses a reactor for a vehicle-mounted converter that includes a coil including a pair of winding portions in which a winding is spirally wound, and an annular magnetic core disposed inside and outside the winding portion. is doing. This magnetic core is formed by joining a plurality of core pieces made of a composite material containing soft magnetic powder and resin with an adhesive or the like and assembling them in an annular shape.

JP 2014-146656 A

As described above, a reactor including a magnetic core formed by joining a plurality of core pieces with an adhesive or the like has a large number of assembly parts and a large number of processes, which causes a reduction in the manufacturability of the reactor. Therefore, improvement of the manufacturability of the reactor is desired.

Also, in an in-vehicle reactor, since the coil becomes hot during use, it is also desired to have excellent heat dissipation.

Therefore, one of the objects of the present invention is to provide a reactor that is excellent in manufacturability and heat dissipation. Another object of the present invention is to provide a reactor manufacturing method capable of easily manufacturing a reactor excellent in heat dissipation.

The reactor which concerns on 1 aspect of this invention is provided with a coil and the magnetic core which is arrange | positioned inside and outside the said coil and forms a closed magnetic circuit.
The magnetic core is an integral molded body made of a composite material including soft magnetic powder and resin.
The coil includes an exposed region where at least a part of an outer peripheral surface of the coil is exposed without being covered with the magnetic core.

The manufacturing method of the reactor which concerns on 1 aspect of this invention concerns on the method of manufacturing a reactor provided with a coil and the magnetic core which is arrange | positioned inside and outside the said coil and forms a closed magnetic circuit, The said reactor is the said It is a reactor which concerns on 1 aspect of this invention, and is provided with the shaping | molding process which forms the said integrally molded object by injection molding.

The above reactor is excellent in manufacturability and heat dissipation. The reactor manufacturing method can easily manufacture a reactor having excellent heat dissipation.

It is a schematic perspective view which shows the reactor of Embodiment 1. FIG. It is a top view of the magnetic core with which the reactor of Embodiment 1 is equipped. It is a side view of the magnetic core with which the reactor of Embodiment 1 is equipped. It is a disassembled perspective view of the coil and insulation interposition part with which the reactor of Embodiment 1 is equipped. It is a schematic perspective view which shows the reactor of Embodiment 2. It is a top view of the magnetic core with which the reactor of Embodiment 2 is equipped. FIG. 6 is a cross-sectional view of the magnetic core provided in the reactor of Embodiment 2 cut along the (VII)-(VII) cutting line shown in FIG. It is a disassembled perspective view of the coil with which the reactor of Embodiment 2 is equipped, and an insulation interposition part.

[Description of Embodiment of the Present Invention]
First, embodiments of the present invention will be listed and described.
(1) The reactor which concerns on 1 aspect of this invention is provided with a coil and the magnetic core which is arrange | positioned inside and outside the said coil and forms a closed magnetic circuit.
The magnetic core is an integrally molded body composed of a composite material containing soft magnetic powder and resin,
The coil includes an exposed region in which at least a part of the outer peripheral surface is exposed without being covered with the magnetic core.

Since the magnetic core is an integrally molded body, the above reactor has a small number of assembly parts, a step such as bonding with an adhesive is unnecessary, the number of steps can be reduced, and the productivity is excellent. In addition, a composite material containing soft magnetic powder and a resin (hereinafter sometimes referred to as a soft magnetic composite material) has a high degree of freedom in shape, and a magnetic core having a desired shape and size can be easily formed. The reactor described above is excellent in manufacturability.

In addition, the reactor described above is configured such that at least a part of the outer peripheral surface of the coil is actively exposed from the magnetic core, the exposed region of the coil is used as a heat dissipation region, and the coil is embedded in the magnetic core, Therefore, the entire region is not covered with a magnetic core. Therefore, the reactor described above is excellent in heat dissipation because the heat of the coil can be easily transmitted to the outside. For example, the above-described reactor may be installed on an installation object having a cooling structure that directly cools the reactor by supplying liquid refrigerant to the reactor, or an installation object that has a cooling structure that cools the reactor by bringing a cooling member into contact with or close to the reactor. Is attached, the heat radiation from the exposed region can be sufficiently performed, and the heat radiation performance can be further improved. The larger the exposed area of the coil, the better the heat dissipation.

(2) As an example of the reactor described above, a form in which the exposed region includes an installation surface of the coil is cited. The installation surface of the coil is a surface arranged facing the installation object of the reactor in the coil.

Since the installation surface of the coil is disposed in contact with or close to the installation target, heat can be radiated to the installation target. Therefore, the said form can make the installation surface of a coil into a thermal radiation area | region, and a thermal radiation area | region is large enough and is excellent by heat dissipation. In particular, when the above-described configuration is attached to an installation target having the above-described cooling structure, heat can be sufficiently radiated from the installation surface of the coil to the installation target, and the heat dissipation is further improved.

(3) As an example of the reactor, the magnetic core includes an inner core portion disposed in the coil and an outer core portion on which the coil is not disposed, and is interposed between the coil and the inner core portion. The form provided with the insulation interposition part which is mentioned.

Since the above-described form includes the insulating interposition part, the insulation between the coil and the magnetic core can be improved. In the above-described embodiment, the insulating intervening part can be used as a mold for the inner core part in the manufacturing process, and a mixture (typically a melt having fluidity) containing soft magnetic powder and resin as raw materials for the soft magnetic composite material. (Hereinafter sometimes referred to as a raw material mixture) is easier to fill than in the case of directly filling the coil, and is more excellent in manufacturability. Furthermore, since the insulating interposition part can also be used as a protective material or shape-retaining material for the coil during filling of the raw material mixture, and the deterioration of the yield can be reduced by preventing damage and deformation of the coil. Excellent.

(4) As an example of the reactor, the magnetic core includes an inner core portion disposed in the coil and an outer core portion in which the coil is not disposed, and the outer core portion has an outer peripheral surface that is the inner core portion. The form provided with the protrusion location which protrudes rather than the outer peripheral surface of a part is mentioned.

In the above-mentioned form, the surface area of the magnetic core is easily increased by having the protruding portion, and the heat dissipation is excellent. When the protruding portion is in contact with or close to the installation surface, heat can be radiated from the protruding portion to the installation target, and the heat dissipation is superior.

(5) As an example of the reactor described above, a mode including a heat radiating member disposed in the exposed region may be mentioned.

The above form is more excellent in heat dissipation because the heat of the coil can be transferred to the outside through the heat dissipation member.

(6) As an example of the above-described reactor, a mode in which the coil includes a heat-sealing resin portion that joins turns adjacent to each other can be cited.

In the above embodiment, since the turns are joined and filled by the heat-sealing resin portion, for example, even when the above-described insulating interposition portion is not provided, it is easy to fill the raw material mixture and is excellent in manufacturability. Moreover, in this case, it is more excellent in manufacturability from the point that the number of assembly parts is small.

(7) As an example of the reactor described above, there is a mode in which a heat radiating member disposed in the exposed region is provided, and the coil includes a heat fusion resin portion that joins the heat radiating member.

In the above embodiment, the heat dissipating member is fixed to the exposed area of the coil, and the heat of the coil is transmitted to the heat dissipating member satisfactorily and has excellent heat dissipation. Moreover, since the said coil is provided with the heat sealing | fusion resin part used as the joining layer of a heat radiating member, the said form does not cause the increase in a number of parts.

(8) As an example of the reactor, the magnetic core includes an inner core portion disposed in the coil, an outer core portion in which the coil is not disposed, and a gap portion provided in the outer core portion. Is mentioned.

The above-mentioned form is difficult to magnetically saturate by the gap part, and a desired inductance can be secured satisfactorily. In addition, since the gap part is provided in the outer core part, it can be easily deaerated during molding, and the magnetic core can be easily molded. Excellent in properties.

(9) As an example of the reactor, a form in which the content of the soft magnetic powder in the composite material is 30% by volume or more and 80% by volume or less can be given.

In the above-mentioned form, the content of the soft magnetic powder satisfies the above specific range, so that the saturation magnetic flux density is increased and the heat dissipation is excellent, and the fluidity of the raw material mixture is excellent and the productivity is excellent.

(10) A method of manufacturing a reactor according to one aspect of the present invention relates to a method of manufacturing a reactor including a coil and a magnetic core that is disposed inside and outside the coil to form a closed magnetic path. Is the reactor according to any one of the above (1) to (9), and includes a molding step of forming the integrally molded body by injection molding.

Since the reactor manufacturing method described above can manufacture a reactor including a coil and a magnetic core simultaneously with the molding of a magnetic core made of an integrally molded body, the number of processes is small and the reactor can be easily manufactured. In particular, injection molding is easier to accurately fill the raw material mixture than in cast molding, it is easy to form a complex three-dimensional shaped product, and a magnetic core having a desired shape can be formed well. The reactor manufacturing method described above can manufacture a reactor having excellent heat dissipation by providing an exposed area on the outer peripheral surface of the coil with high productivity.

(11) As an example of the manufacturing method of the reactor, an assembly including an insulating intermediate portion including a cylindrical portion and the coil are assembled, and a braid covering the inner peripheral surface of the coil with the cylindrical portion is prepared. In the molding step, a form in which the cylindrical part is filled with the composite material (raw material mixture) can be mentioned.

The cylindrical part of the insulating intermediate part is used as a molding die for the part (inner core part) arranged in the coil of the magnetic core, so that the raw material mixture can be easily filled in the cylindrical part, Easy to mold. Further, the coil can be protected and retained by the cylindrical portion, and a decrease in yield due to damage or deformation of the coil can be reduced. Therefore, the said form can manufacture the reactor excellent in heat dissipation easily and with sufficient productivity.

(12) As an example of the manufacturing method of the reactor described above, a coil in which adjacent turns are joined by a heat-sealing resin is prepared as the coil. In the molding step, the composite material ( The form which fills a raw material mixture) is mentioned.

In the above embodiment, the gap between adjacent turns is joined and filled with the heat-sealing resin, and the inner peripheral surface of the coil can be used as it is for the molding die. Therefore, even if the above-mentioned form is not provided with the above-mentioned insulation interposition part, it is easy to fill the raw material mixture in the coil, the magnetic core of the integrally molded body can be easily formed, the number of assembly parts is small, and the heat dissipation Can be manufactured easily and with high productivity.

[Details of the embodiment of the present invention]
Embodiments of the present invention will be specifically described below with reference to the drawings. The same reference numerals in the figure indicate the same names. In the following description, the case where the lower surface of reactor 1A shown in FIG. 1 and the lower surface of reactor 1B shown in FIG. This installation state is an example, and the side surfaces and upper surfaces of the reactors 1A and 1B can be used as the installation surfaces.

[Embodiment 1]
A reactor 1A according to the first embodiment will be described with reference to FIGS.
(Reactor)
-Overall structure The reactor 1A of Embodiment 1 is provided with the coil 2A and the magnetic core 3A arrange | positioned inside and outside of the coil 2A, as shown in FIG. Reactor 1A is used by being attached to an installation target (not shown) such as a converter case.

One of the features of the reactor 1A of the first embodiment is that the magnetic core 3A is an integral molded body made of a composite material (soft magnetic composite material) containing soft magnetic powder and resin. Further, the reactor 1A is such that at least a part of the outer peripheral surface of the coil 2A, in this example, substantially the entire outer peripheral surface of the winding portions 2a and 2b described later is exposed without being covered by the magnetic core 3A. One of the features. Hereinafter, each component will be described in detail.

Coil The coil 2A has a cylindrical winding portion 2a formed by spirally winding one winding 2w as shown in FIGS. 1 and 4 and another winding 2w spirally. A cylindrical winding portion 2b formed by winding and a connecting portion 2j obtained by joining one end portions of the winding portions 2a and 2b are provided. The winding parts 2a and 2b are arranged in parallel (side by side) so that their axes are parallel.
One end portions of the winding portions 2a and 2b and the vicinity thereof are drawn away from the outer peripheral surfaces (here, upper surfaces) of the winding portions 2a and 2b so that the one end portions of the winding portions 2a and 2b are in contact with each other. The vicinity of one end of one winding part 2a is bent toward one end of the other winding part 2b. Therefore, the connecting portion 2j shown in FIG. 1 does not interfere with the outer peripheral surface (here, the upper surface) of the magnetic core 3A. For joining the one end portions, welding or pressure welding can be used. In addition, a connecting material (not shown) made of a conductive material such as copper can be separately used for joining the one end portions.
The other end portions of the winding portions 2a and 2b are both drawn out from the winding portions 2a and 2b in an appropriate direction, and a terminal fitting (not shown) or the like is attached to an external device (not shown) such as a power source. )).

The winding 2w in this example is a covered rectangular wire having a rectangular cross section provided with a conductor wire made of copper or the like and an insulating coating made of polyamideimide or the like covering the outer periphery of the conductor wire. Each winding part 2a, 2b is an edgewise coil of the same shape and the same size. Specifically, each winding part 2a, 2b is a rectangular cylindrical body with rounded corners (FIG. 4), and the outer peripheral surface thereof has four curved surfaces arranged at the corners and four connecting the curved surfaces. With two planes. Of the four planes, the lower surface is an installation surface of the coil 2 </ b> A arranged to face the installation target, and in this example, the lower surface is arranged so as to be in contact with the heat radiating member 6 (FIG. 1) described later. Since the heat dissipating member 6 is disposed in contact with the installation target, the installation surface of the coil 2A is disposed close to the installation target.

In the coil 2A of this example, the end surfaces of the winding portions 2a and 2b are covered with the inner surface of the outer core portion 32A, but substantially the entire outer peripheral surface of the winding portions 2a and 2b is not covered with the magnetic core 3A and exposed. To make an exposed area. That is, the exposed region of the coil 2A in this example includes not only the installation surface of the coil 2A but also the remaining three planes. Therefore, the coil 2A can sufficiently dissipate heat to the outside including the installation target.

Magnetic Core 3A, as shown in FIG. 1, includes inner core portions 31a and 31b disposed in the winding portions 2a and 2b of the coil 2A, respectively, and an outer core portion 32A in which the coil 2A is not disposed. When the coil 2A is excited, a closed magnetic circuit is formed. As shown in FIG. 2, the outer core portion 32A in this example is continuous to the individual end portions 32a and 32b that are continuous to one end portions of the inner core portions 31a and 31b, respectively, and to the other end portions of the inner core portions 31a and 31b. In addition, a connecting end portion 32c that connects both portions 31a and 31b and a gap portion 3g are provided. The individual end portions 32a and 32b are not connected to each other, and there is a gap between them. This gap is defined as a gap portion 3g. The magnetic core 3 </ b> A has an outer core portion 32 </ b> A and inner core portions 31 a and 31 b that are integrally formed of a soft magnetic composite material, and has a ‘P’ shape in plan view.

.. Constituent material The soft magnetic composite material constituting the magnetic core 3A includes soft magnetic powder and resin.
The particles constituting the soft magnetic powder are metal particles made of soft magnetic metals such as iron group metals such as pure iron and iron-based alloys (Fe-Si alloys, Fe-Ni alloys, etc.), and phosphoric acid around the metal particles. Examples thereof include coated particles having an insulating coating composed of salt or the like, and particles made of a nonmetallic material such as ferrite.

Examples of the content of the soft magnetic powder in the soft magnetic composite material include 30% by volume or more and 80% by volume or less. The higher the content, the higher the saturation magnetic flux density and the better the heat dissipation, and the lower limit can be 50% by volume or more, further 55% by volume or more, and 60% by volume or more. When the content is small to some extent, when filling the raw material (raw material mixture) of the soft magnetic composite material into the mold, it is excellent in fluidity and easy to fill the mold, and an improvement in manufacturability can be expected, and the upper limit is 75 volumes. % Or less, and further 70% by volume or less.

Examples of the average particle size of the soft magnetic powder include 1 μm or more and 1000 μm or less, and further 10 μm or more and 500 μm or less.

Examples of the resin in the soft magnetic composite material include thermosetting resins such as epoxy resins, phenol resins, silicone resins, and urethane resins, polyphenylene sulfide (PPS) resins, polyamide (PA) resins (for example, nylon 6, nylon 66, Nylon 9T), liquid crystal polymer (LCP), polyimide resin, thermoplastic resin such as fluororesin, room temperature curable resin, low temperature curable resin, and the like. In addition, BMC (Bulk molding compound) in which calcium carbonate or glass fiber is mixed with unsaturated polyester, millable silicone rubber, millable urethane rubber, or the like can be used.

The soft magnetic composite material can contain a filler powder made of a nonmagnetic material such as ceramics such as alumina and silica, in addition to the soft magnetic powder and the resin. In this case, for example, heat dissipation can be improved. Examples of the content of the filler powder in the soft magnetic composite material include 0.2% by mass to 20% by mass, 0.3% by mass to 15% by mass, and 0.5% by mass to 10% by mass.

..Shape The inner core portions 31a and 31b constituting the magnetic core 3A of this example, the individual end portions 32a and 32b, which are the outer core portion 32A, and the connecting end portion 32c are all rectangular parallelepiped (FIGS. 1 to 3). . The inner core portions 31a and 31b have the same shape and the same size, and the individual end portions 32a and 32b also have the same shape and the same size. As shown in FIGS. 1 and 2, the connecting end portion 32c is larger than the individual end portions 32a and 32b (the width W _32c of the connecting end portion _32c > the sum of the widths W ₃₂ of the individual end portions 32a and 32b).

Further, the outer core portion 32A provided in the magnetic core 3A of this example includes a protruding portion whose outer peripheral surface protrudes from the outer peripheral surfaces of the inner core portions 31a and 31b. In this example, each of the individual end portions 32a and 32b and the connecting end portion 32c has a protruding portion that protrudes outward from the peripheral edge over the entire peripheral edge of the inner core portions 31a and 31b.

Specifically, as shown in FIG. 2, the individual end portions 32a and 32b and the connecting end portion 32c are in the axial direction of the inner core portions 31a and 31b with respect to the outer peripheral surfaces of the inner core portions 31a and 31b (in FIG. Direction) and a protruding portion that protrudes in the parallel direction of the inner core portions 31a and 31b (the left-right direction in FIG. 2). The width W ₃₂ of the individual end portions 32a and 32b is larger than the width W ₃₁ of the inner core portions 31a and 31b.

Further, as shown in FIG. 3, the individual end portions 32a and 32b and the connecting end portion 32c are in the axial direction of the inner core portions 31a and 31b with respect to the outer peripheral surfaces of the inner core portions 31a and 31b. ) And a projecting portion that projects in a direction (vertical direction in FIG. 3) perpendicular to the installation target, and the magnetic core 3A has an H shape in a side view. The height h ₃₂ of the individual end portions 32a and 32b and the connecting end portion 32c is larger than the height h ₃₁ of the inner core portions 31a and 31b.

In this example, the widths W ₃₁ , W _{32c, and the} like are adjusted so that the width W _32c (= 2 × W ₃₁ + the gap 3g) of the coupling end 32c and the width of the coil 2A are substantially equal. ing. Also, the installation surface (lower surface) of the individual end portions 32a and 32b and the connecting end portion 32c and the opposing surface (upper surface), the installation surface (lower surface) of the winding portions 2a and 2b of the coil 2A, and the opposing surface (upper surface). Are adjusted so that the heights h ₃₁ and h ₃₂ are substantially flush with each other. The outer shape of such a reactor 1A is a rectangular parallelepiped shape having a width W _32c and a height h ₃₂ (FIG. 1), and the installation surface of the reactor 1A is the installation surface of the coil 2A and the outer core portion 32A of the magnetic core 3A. It is formed with the installation surface.

.. Gap portion In the outer core portion 32A of this example, a gap provided between the opposing surfaces of both the individual end portions 32a and 32b is defined as a gap portion 3g. The size of the gap may be appropriately selected so that the reactor 1A has a desired inductance.

The gap portion 3g can be provided with a gap material (not shown) made of a material having a relative permeability lower than that of the soft magnetic composite material in addition to the air gap as shown in FIG. Examples of the constituent material of the gap material include ceramics such as alumina, nonmagnetic materials such as resin (for example, PPS resin), composite materials including soft magnetic powder and resin, and elastic materials such as various rubbers. The gap material may be inserted and disposed in the gap between the individual end portions 32a and 32b, or may be integrally formed when the magnetic core 3A is formed.

.. Other members: Insulating intervening portion The reactor 1A in this example includes an insulating intervening portion 5A interposed between the winding portions 2a, 2b of the coil 2A and the inner core portions 31a, 31b of the magnetic core 3A. Prepare. The insulating interposition part 5A is made of an insulating material and improves the insulation between the winding parts 2a, 2b and the inner core parts 31a, 31b. Furthermore, in the reactor 1A, the insulating interposition part 5A is used as a mold during the manufacturing process.

The material, shape, size, etc. of the insulating interposition part 5A can be selected as appropriate. As shown in FIG. 4, the insulation intervening portion 5 </ b> A in this example has a configuration in which a pair of split members 50 α and 50 β that can be split in the axial direction of the coil 2 </ b> A are combined and integrated. With this configuration, the insulating intermediate portion 5A can be easily assembled to the coil 2A, and the manufacturability of the reactor 1A is excellent.

The split members 50α and 50β have the same basic configuration, and are short cylindrical portions 51 and 51 interposed between the winding portions 2a and 2b of the coil 2A and the inner core portions 31a and 31 of the magnetic core 3A. , And a frame plate portion 52 having a pair of cylindrical portions 51 and 51 projecting therefrom. The frame plate portion 52 is disposed in contact with both the end surfaces of the winding portions 2a and 2b and the inner surface of the outer core portion 32A (the individual end portions 32a and 32b or the connecting end portion 32c). A pair of opening parts 52h and 52h are provided in the frame plate part 52 apart from each other, and the cylindrical part 51 is connected to the peripheral edge forming the opening part 52h. The frame plate portion 52 is interposed between the end surfaces of the winding portions 2a and 2b and the inner surface of the outer core portion 32A, and improves the insulation between them.

A series of parallel cylindrical portions 51, 51 formed by combining the split members 50α, 50β are used as molds for the inner core portions 31a, 31b in the manufacturing process of the reactor 1A, respectively. It is used as a mold for forming the inner surface of the outer core portion 32A. Therefore, the insulating interposition part 5A is a molded body from which the raw material mixture does not leak. Specifically, the outer peripheral surfaces of the series of cylindrical portions 51, 51 cover the entire inner peripheral surfaces of the winding portions 2a, 2b of the coil 2A, respectively. In addition, the insulation intervening portion 5A of this example is configured such that both the split members 50α and 50β can be engaged with each other and can maintain the engaged state when assembled to the coil 2A. Here, the other end portions of the cylindrical portions 51 and 51 of the one split member 50α and the other end portions of the cylindrical portions 51 and 51 of the other split member 50β are stepped. By the series of engaged cylindrical portions 51, 51, the raw material mixture can be prevented from leaking between turns forming the winding portions 2a, 2b of the coil 2A. The size of the frame plate portion 52 is equal to the size of one surface of the connection end portion 32c (W _32c × h ₃₂ ), and is large enough to cover each end surface of the winding portions 2a and 2b arranged in parallel. (FIG. 1).

Examples of the constituent material of the insulating intermediate portion 5A include resins having excellent insulating properties, for example, thermoplastic resins such as PPS resin, polytetrafluoroethylene (PTFE) resin, LCP, PA resin, and polybutylene terephthalate (PBT) resin. The insulating intervening portion 5A can be easily manufactured in a desired shape using a known molding method such as injection molding.

... Heat radiating member The reactor 1A of this example is provided with the heat radiating member 6 arrange | positioned in the exposed area | region of winding part 2a, 2b of coil 2A. The heat radiating member 6 in this example is a flat plate, and one surface (here, the upper surface) is a support surface that integrally supports the installation surface of the coil 2A and the installation surface of the magnetic core 3A (FIGS. 1 and 3). . The opposite surface (the lower surface in this case) of the support surface is a mounting surface to the installation target. FIG. 1 shows a case where the size of the support surface of the heat dissipation member 6 is substantially equal to the total area of the installation surface of the coil 2A and the installation surface of the magnetic core 3A.

The heat dissipating member 6 can be arranged in any size at any position in the exposed area of the coil 2A in addition to the installation surface of the coil 2A. For example, the heat radiating member 6 can be arranged on the side surface or the surface facing the installation surface (upper surface) instead of or together with the installation surface of the winding parts 2a, 2b. The shape and size of the heat dissipating member 6 can be appropriately changed according to the exposed region. For example, in order to further increase the surface area, it is possible to provide fins or comb teeth portions interposed between turns.

As the constituent material of the heat radiating member 6, a material having excellent thermal conductivity can be selected as appropriate. For example, a nonmetal such as ceramics such as alumina is excellent in insulation from the coil 2A. Or if it is metals, such as aluminum and an aluminum alloy, heat conductivity is high and it is excellent in heat dissipation. In the case of the metal heat dissipating member 6, an insulating layer can be provided at a contact point with the exposed region of the coil 2A.

When the heat dissipation member 6 is fixed to the exposed area of the coil 2A with a bonding layer (not shown) made of an adhesive or the like, it is difficult to be displaced from a predetermined position. If the adhesive is insulative, the insulation between the coil 2A and the coil 2A can be improved even when the heat dissipation member 6 is made of metal.

In addition, as the winding 2w, one having a heat-sealing layer made of a heat-sealing resin (see Embodiment 3 described later) can be used. In this case, the coil 2A is heated at an appropriate time to melt the heat-sealing layer, and the heat dissipation member 6 can be fixed to the coil 2A by the heat-sealing resin portion. If a heat-sealing resin portion (not shown) interposed between the exposed region of the coil 2A and the heat radiating member 6 is used for joining the heat radiating member 6, the coil 2A itself includes a bonding layer, and therefore, by an adhesive or the like. The bonding layer can be omitted.

... Sensor Other than that, the reactor 1A can include a sensor (not shown) for measuring the physical quantity of the reactor such as a temperature sensor, a current sensor, a voltage sensor, and a magnetic flux sensor (the same applies to the second embodiment described later). .

(Reactor manufacturing method)
Reactor 1A of Embodiment 1 can be manufactured by filling a raw material mixture into and out of coil 2A arranged in a mold having a predetermined shape, and molding magnetic core 3A as an integrally molded body. As a manufacturing method of a reactor of an embodiment, it is mentioned that a molding process for forming the integral molded body by injection molding is included. As a more specific manufacturing method, a preparation process for preparing the coil 2A, an arrangement process for arranging the coil 2A in the mold, and a raw material mixture inside and outside the coil 2A in the mold are filled with a composite material. And a demolding step of taking out the reactor 1A including the coil 2A and the magnetic core 3A formed from the integrally molded body from the molding die. Details of each step will be described below.

-Preparation process In this process, the coil 2A produced by winding the winding 2w is prepared. Both ends of the winding 2w are kept extended in the winding direction, and after forming the magnetic core 3A, bending, formation of the connecting portion 2j, and the like can be appropriately performed. In this case, for example, if a molding die having a through hole through which the end of the winding 2w is inserted is prepared, the magnetic core 3A can be molded with the end of the winding 2w arranged outside the molding die, and the winding 2w It is easy to mold without getting in the way. When manufacturing the reactor 1A provided with the insulation interposition part 5A, the insulation interposition part 5A provided with the above-described tubular part 51 is prepared, and the divided members 50α and 50β and the coil 2A are assembled, that is, the winding part 2a, A braided part is prepared by inserting the tubular part 51 into 2b and covering the inner peripheral surfaces of the winding parts 2a, 2b with the series of tubular parts 51, 51 described above.

Arrangement Step In this step, a mold that can mold the magnetic core 3A having a predetermined shape is prepared, and the coil 2A is disposed in the mold. When manufacturing the reactor 1A provided with the insulation interposition part 5A, the above-mentioned assembly is arrange | positioned to a shaping | molding die. It is preferable to appropriately support the coil 2A and the assembly so that the position in the mold does not shift when the raw material mixture is filled. As the mold, for example, at least a part of the outer peripheral surface of the coil 2 </ b> A is not covered with the magnetic core 3 </ b> A that is an integrally molded body and can be exposed. As such a mold, for example, it can be divided into upper and lower parts, and one mold is a rectangular box, the arrangement space of the coil 2A or the assembly, and the outer peripheral surfaces of the individual end portions 32a and 32b. Including an inner wall that forms a gap portion 3g and an inner wall that forms an outer peripheral surface of the connecting end portion 32c. In this example, together with this mold, the insulating interposition part 5A is also used for molding the magnetic core 3A as described above, whereby the one mold can be made into a simple shape and the assembly can be easily arranged. In the case of manufacturing a reactor in which the gap material is integrally formed with the magnetic core 3A, the gap material can also be disposed in the mold and integrated with the formation of the magnetic core 3A.

Forming step In this step, a composite material (raw material mixture) containing soft magnetic powder and resin is prepared, filled in a mold, and solidified to form the composite material, which is formed inside and outside the coil 2A. The magnetic core 3A to be disposed is molded. Various methods such as injection molding, MIM (Metal Injection Molding), and cast molding can be used for molding the magnetic core 3A. In particular, injection molding and MIM can satisfactorily fill a raw material mixture, typically in a molten state with fluidity, into a mold having a complicated three-dimensional shape. Can be molded with high accuracy. When manufacturing the reactor 1A provided with the insulation interposition part 5A, the raw material mixture is filled into a series of cylindrical parts 51, 51 formed in parallel by the two divided members 50α, 50β. By doing so, the inner core portions 31a and 31b can be formed in contact with the inner surfaces of the series of cylindrical portions 51 and 51, respectively.

In order to mold the magnetic core 3A provided with the gap portion 3g, it is possible to provide a starting point for filling the raw material mixture at a position far from the position where the gap portion 3g is formed. The black arrows in FIG. 4 schematically show the filling route of the raw material mixture. For example, as shown in FIG. 4, the vicinity of both openings 52h provided in the frame plate portion 52 of one divided material 50β arranged in the mold is used as a starting point for filling the raw material mixture, and the frame plate portion of the other divided material 50α Filling the raw material mixture may be mentioned with the partition arranged so as to be orthogonal to 52 as the end point of filling of the raw material mixture. Thus, the one-point gate with the position far from the gap 3g as the raw material mixture filling start position and the vicinity of the partition for forming the gap 3g (opposite surfaces of the individual end portions 32a and 32b) as the raw material mixture filling end position. Therefore, it is easy to deaerate, and inclusion of voids can be suppressed. The molding die may be provided with a deaeration hole near the molding part of the gap portion 3g. The connecting end portion 32c is formed at the filling start location, the individual end portions 32a and 32b are formed at the filling end location, and the inner core portions 31a and 31b are formed in the series of the cylindrical portions 51 and 51 arranged in parallel. , These are united.

-Demolding process The magnetic core 3A is molded by the molding process, and an integral body in which the coil 2A is supported by the magnetic core 3A and the insulating intervening portion 5A as appropriate can be molded. The reactor 1A including the coil 2A and the magnetic core 3A is obtained.

-Other process About the removed monolith, if the heat radiating member 6 is suitably joined to the exposed area of the coil 2A, the reactor 1A to which the heat radiating member 6 is joined is obtained.

(Main effect)
In the reactor 1A of the first embodiment, the magnetic core 3A including the inner core portions 31a and 31b and the outer core portion 32A is an integrally molded body, so that the number of assembly parts and the number of processes are small, and the productivity is excellent. Although the reactor 1A in this example has a three-dimensional shape in which the outer core portion 32A has a protruding portion protruding from the inner core portions 31a and 31b, the magnetic core 3A is easily formed by injection molding, and It can be molded accurately and has excellent manufacturability.

And since reactor 1A of Embodiment 1 has the exposure area | region where coil 2A functions as a thermal radiation area | region, the heat | fever of coil 2A can be easily tell | transmitted outside and it is excellent in heat dissipation. The reactor 1A of this example is more excellent in heat dissipation from the following points.
1. The substantially entire region of the winding portions 2a and 2b is an exposed region, and the heat dissipation region is sufficiently wide.
2. The exposed area includes the installation surface of the coil 2A, and heat can be radiated to the installation target. When the installation target has a cooling structure, the installation surface of the coil 2A can be sufficiently cooled by the installation target.
3. The heat dissipating member 6 is disposed on the installation surface of the coil 2A, and the heat dissipating member 6 is interposed between the installation surface and the installation target, so that heat can be radiated better depending on the installation target.
4). The outer core portion 32A has a protruding portion, and the outer core portion 32A has a large surface area.
5. The protruding portion has an installation surface, and the magnetic core 3A can also dissipate heat to the installation target.
6). The heat dissipating member 6 is disposed on the installation surface of the protruding portion, and heat can be better radiated from the magnetic core 3A to the installation target.

In addition, the reactor 1 </ b> A of this example includes the insulating interposition part 5 </ b> A, and the insulating interposition part 5 </ b> A can be used as a molding die for the magnetic core 3 </ b> A in the manufacturing process of the reactor 1 </ b> A, and has the following effects.
1. The insulation between the winding portions 2a and 2b of the coil 2A and the inner core portions 31a and 31b of the magnetic core 3A is excellent.
2. The coil 2A can be mechanically protected when the magnetic core 3A is molded.
3. It is possible to prevent the raw material mixture from leaking from between the turns constituting the winding portions 2a and 2b when the magnetic core 3A is formed.

Furthermore, the reactor 1A of this example has the following effects.
1. Since the outer core portion 32A includes the gap portion 3g, the magnetic core 3A can be provided with good deaeration during molding and less defects such as voids.
2. Since the outer core portion 32A has the protruding portion, the length along the axial direction of the coil 2A in the outer core portion 32A can be shortened as compared with the case where the protruding portion does not have, and the size can be reduced. .
3. Since the magnetic core 3A has the installation surface, the stability of the installation state is excellent.

The manufacturing method of the reactor of embodiment can manufacture the reactor 1A excellent in the above-mentioned heat dissipation with few processes. In this example, by using the insulating intervening portion 5A as a part of the molding die, the inner core portions 31a and 31b can be easily and accurately molded, and the coil 2A is formed when the magnetic core 3A is molded as described above. Can be mechanically protected, the occurrence of defects due to damage of the coil 2A and the like can be reduced, and the reactor 1A can be manufactured with high productivity.

[Embodiment 2]
A reactor 1B according to the second embodiment will be described with reference to FIGS.
In the first embodiment, the coil 2A has two winding portions 2a and 2b, and the magnetic core 3A has two inner core portions 31a and 31b and one gap portion 3g. A reactor 1B according to the second embodiment includes a coil 2B and a magnetic core 3B that is disposed inside and outside the coil 2B to form a closed magnetic path, and the magnetic core 3B includes an inner core portion 31 and an outer core portion 32B. The point which is the integrally molded object comprised from the soft-magnetic composite material is common in Embodiment 1. The reactor 1B is different from the first embodiment in that the coil 2B includes only one winding part and the magnetic core 3B is similar to a so-called EE type core. Hereinafter, these differences will be described in detail, and detailed descriptions of common configurations and effects will be omitted.

(Reactor)
-Coil The coil 2B is provided with one cylindrical winding part formed by winding one winding 2w spirally as shown in FIG. Each end portion of the winding 2w is drawn out from the winding portion in an appropriate direction. FIG. 8 shows an example in which both end portions of the winding 2w are arranged on the same end face side of the winding portion. The winding part of the coil 2B of this example is an edgewise coil formed of a covered rectangular wire, like the coil 2A of the first embodiment, and is a rectangular cylindrical body with rounded corners, and as its outer peripheral surface It has four planes, and the lower surface is an installation surface of the coil 2B.

In the coil 2B of this example, as shown in FIG. 5, among the four planes of the end face of the winding part and the outer peripheral face, most of the two faces orthogonal to the installation face are covered with the inner face of the outer core part 32B. The installation surface (lower surface) and the opposite surface (upper surface) are exposed without being covered with the magnetic core 3B to form an exposed region. Since the coil 2B includes the installation surface in the exposed area, the coil 2B can sufficiently dissipate heat to the outside including the installation target, as in the first embodiment.

-Magnetic core The magnetic core 3B is provided with the inner core part 31 arrange | positioned in the winding part of the coil 2B, and the outer core part 32B in which the coil 2B is not arrange | positioned, as shown in FIG. As shown in FIG. 6, the outer core portion 32 </ b> B of this example connects the connection end portions 32 c and 32 c continuous to each end portion of the inner core portion 31 and one side edge of both the connection end portions 32 c, An integrated outer peripheral portion 32s arranged parallel to the axial direction of 31 (vertical direction in FIG. 6), and an individual outer peripheral portion that is continuous with the other side edge of each of the connecting end portions 32c and 32c and is opposed to the integrated outer peripheral portion 32s. 32s ₁ and 32s ₂ and a gap portion 3g. The magnetic core 3B is a core having a shape similar to an EE type core in which the outer core portion 32B and the inner core portion 31 are integrally formed of a soft magnetic composite material.

The inner core portion 31 constituting the magnetic core 3B of this example, the connecting end portions 32c and 32c, which are the outer core portion 32B, the integrated outer peripheral portion 32s, and the individual outer peripheral portions 32s ₁ and 32s ₂ are all rectangular parallelepiped (FIG. 5). To FIG. 7). The two connecting end portions 32c and 32c have the same shape and the same size, and the individual outer peripheral portions 32s ₁ and 32s ₂ have the same shape and the same size. The gap portion 3g is a gap provided between the two individual outer peripheral portions 32s ₁ and 32s ₂ . The sum of the size of the gap portion 3g and the total length of the individual outer peripheral portions 32s ₁ and 32s ₂ (the length in the vertical direction in FIG. 6) is adjusted to be equal to the length (the same) of the integral outer peripheral portion 32s. is doing.

If the gap portion 3g is an air gap, a part of the outer peripheral surface of the winding portion of the coil 2B is exposed from the gap between the two individual outer peripheral portions 32s ₁ and 32s ₂ , but this portion (the winding portion) The central portion in the axial direction) is also very small, and is considered not to function sufficiently as a heat dissipation region. Therefore, in the reactor 1B of the second embodiment, even if an air gap is provided, a region other than the air gap, here, the installation surface and its opposite surface are positively exposed as described above, and a sufficient heat dissipation region is provided. It is set as the structure to have. When the air gap is provided, the exposed region of the coil 2B is a region that is sufficiently wider than the exposed portion based on the air gap. Although it depends on the shape of the magnetic core 3B, it is at least 1/4 of the outer peripheral surface of the coil 2B, and further 1/2 It is preferable to have the above area.

Similar to the magnetic core 3 </ b> A of the first embodiment, the magnetic core 3 </ b> B of this example includes a protruding portion where the outer peripheral surface of the outer core portion 32 </ b> B protrudes from the outer peripheral surface of the inner core portion 31. Each of the connecting end portions 32 c and 32 c includes a protruding portion that protrudes outward from the peripheral edge over the entire peripheral edge of the inner core portion 31. In FIG. 6, the part which protrudes in the direction orthogonal to the axial direction of the inner core part 31 is shown. The heights of the integrated outer peripheral portion 32s and the individual outer peripheral portions 32s ₁ and 32s ₂ that are continuous to the connecting end portions 32c and 32c are also higher than the height of the inner core portion 31 (FIG. 7).

Furthermore, the installation surface (lower surface) of the coupling end portions 32c and 32c, the outer peripheral portions 32s, 32s ₁ and 32s ₂ and its opposing surface (upper surface) and the installation surface (lower surface) of the winding portion of the coil 2B and its opposing surface (upper surface) And the height of the core portions 31 and 32B are adjusted so as to be substantially flush with each other. The outer shape of such a reactor 1B is a rectangular parallelepiped (FIG. 5), and the installation surface of the reactor 1B is formed by the installation surface of the coil 2B and the installation surface of the outer core portion 32B of the magnetic core 3B.

-Insulation interposition part The reactor 1B of this example is provided with the insulation interposition part 5B interposed between the coil 2B and the inner core part 31 of the magnetic core 3B similarly to Embodiment 1. FIG. The basic configuration, constituent material, function, usage, and the like of the insulating interposition part 5B are the same as those of the insulating interposition part 5A of the first embodiment. Describing the schematic configuration, the insulation intervening portion 5B is an assembly formed by combining a pair of divided members 50γ and 50δ as shown in FIG. Each of the dividing members 50γ and 50δ has one cylindrical portion 51 and a frame plate portion 52. The cylindrical parts 51, 51 of both divided members 50γ, 50δ are engaged with each other. A series of cylindrical parts 51 and 51 are utilized for the shaping | molding die of the inner core part 31, and the frame board parts 52 and 52 are utilized for the shaping | molding die of the connection end parts 32c and 32c.

-Heat dissipation member The reactor 1B of this example is provided with the heat dissipation member 6 arrange | positioned in the exposed area | region of the coil 2B similarly to Embodiment 1. FIG. The heat radiating member 6 in this example is a flat plate material as in the first embodiment, is fixed to the installation surface of the coil 2B by a bonding layer, and is interposed between the coil 2B and the magnetic core 3B and the installation target.

(Reactor manufacturing method)
Reactor 1B of Embodiment 2 can be manufactured by the manufacturing method demonstrated in Embodiment 1, for example. In particular, it may be referred to the case where the insulating interposition part 5A is provided, and the details are omitted.

In particular, in order to mold the magnetic core 3B having the gap portion 3g, for example, the following mold can be used. This molding die can be divided into upper and lower parts, and one of the molds is a rectangular box, and includes a space in which the coil 2B is disposed, the outer peripheral surfaces of the coupling end portions 32c and 32c, and the outer peripheral portions 32s, An inner wall for molding the outer peripheral surfaces of 32s ₁ and 32s ₂ , an integral molding wall for molding the inner peripheral surface of the integral outer peripheral portion 32s, and an individual molding wall for molding the inner peripheral surfaces of the individual outer peripheral portions 32s ₁ and 32s ₂ And a partition provided between the individual forming wall and the inner wall and forming a gap 3g (opposite surfaces of the individual outer peripheral portions 32s ₁ and 32s ₂ ). In this example, the insulating interposition part 5B is also used for molding the magnetic core 3B together with the mold as in the first embodiment. When the magnetic core 3B is formed as a one-point gate provided with a raw material mixture filling start position at a position far from the position where the gap portion 3g is formed, it is easy to deaerate and the inclusion of voids can be suppressed. The black arrows in FIG. 8 schematically show the filling route of the raw material mixture. In FIG. 8, in one side surface orthogonal to the installation surface (lower surface) of the outer peripheral surface of the coil 2B, the central portion in the axial direction of the coil 2B is used as a starting point for filling the raw material mixture, and the other side surface facing the one side surface is shown. Of these, the vicinity where the above-mentioned partition is disposed is the filling end location, the vicinity of the frame plate portion 52 of each divided material 50γ, 50δ is the branch location of the raw material mixture, and the inside of the cylindrical portions 51, 51 of the insulating intermediate portion 5B The raw material mixture is filled so as to reach the vicinity of the above-mentioned partition.

(Main effect)
Similarly to the first embodiment, the reactor 1B according to the second embodiment is an integral molded body with the magnetic core 3B including the inner core portion 31 and the outer core portion 32B. Therefore, the number of assembly parts and the number of processes are small and the productivity is excellent. . Although the reactor 1B of this example is a three-dimensional shape in which the outer core portion 32B has a protruding portion, the magnetic core 3B can be easily and accurately formed by injection molding, and is excellent in manufacturability.

And the reactor 1B of Embodiment 2 is excellent in heat dissipation since the coil 2B has the exposed area | region which functions as a heat radiation area | region similarly to Embodiment 1. FIG. The reactor 1B of this example includes (1) including the installation surface of the coil 2B and its opposing surface in the exposed region, (2) having the heat radiating member 6, and (3) the projecting portion and installation surface of the outer core portion 32B. Since it has, it is more excellent in heat dissipation.

In addition, the reactor 1B of this example has the same effect as that of the first embodiment (including good insulation, mechanical protection of the coil 2B, prevention of leakage of the raw material mixture), gap portion 3g on the outer core portion 32B, and the like. Effects (inhibition of voids), and effects (downsizing and stabilization of the installation state) in which the outer core portion 32B has a protruding portion can be achieved.

[Embodiment 3]
A heat-sealing resin portion for joining the turns adjacent to each other in the coils 2A and 2B in place of or together with the insulating interposed portions 5A and 5B provided in the reactors 1A and 1B of the first and second embodiments (FIG. Not shown).

In this embodiment, the winding 2w having a heat fusion layer is used. After winding the winding 2w as appropriate, the heat fusion layer is melted by heating at an appropriate time, and adjacent turns are joined together with a heat fusion resin. In this coil, since the heat-sealing resin portion is interposed between the turns, the turns are not substantially deviated from each other, and the coil is not easily deformed.

Examples of the heat-sealing resin constituting the heat-sealing layer include thermosetting resins such as epoxy resin, silicone resin, and unsaturated polyester.

If the insulation intervening portions 5A and 5B are not provided, the above-described heat-sealed coil is prepared and placed in a mold, and the raw material mixture is filled inside and outside of this coil, and the magnetic core 3A or magnetic core 3B or the like is molded. A gap between adjacent turns is filled with the heat-sealing resin so that the raw material mixture is not exposed from between the turns, and the inner peripheral surface of the coil can be used as a molding die. Therefore, this form has fewer assembly parts and is superior to manufacturability. Further, by omitting the insulating intervening portions 5A and 5B, a small reactor can be obtained.

In the case where the heat fusion part and the insulating interposition parts 5A and 5B are provided, it is easier to prevent the coil from being deformed during the manufacturing process and the like, and it is easy to handle.

[Modification]
At least one of the following modifications can be made to the first to third embodiments.
(1) The coil 2A including the pair of winding portions 2a and 2b is formed by one continuous winding 2w.
When the one surface (upper surface) facing the installation surface of the coupling end 32c is flush with the one surface (upper surface) facing the installation surface of the coil 2A, like the magnetic core 3A described in the first embodiment, the outer core portion At the time of molding 32A, it is preferable that the portion connecting both winding portions 2a and 2b does not get in the way. For example, the part which connects both winding part 2a, 2b is bent above winding part 2a, 2b.
(2) The gap material is provided in the inner core portions 31a, 31b, 31 of the magnetic cores 3A, 3B.
In this case, a gap material is fixed to one of the divided members 50α and 50γ of the insulating intervening portions 5A and 5B, or one opening of the cylindrical portion 51 of the divided members 50α and 50γ is closed to form a bottomed cylindrical portion. The bottom plate portion may be a gap material.
(3) A gapless score that does not include the gap portion 3g.
(4) A coil having only one winding portion is provided for the annular magnetic core 3A. For example, a coil is disposed on one inner core portion 31a of the magnetic core 3A described in the first embodiment, and the other inner core portion 31b is a part of the outer core portion.

The present invention is not limited to these exemplifications, but is defined by the scope of the claims, and is intended to include all modifications within the scope and meaning equivalent to the scope of the claims.

The reactor of the present invention includes various converters such as an in-vehicle converter (typically a DC-DC converter) and an air conditioner converter mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, and a fuel cell vehicle. It can be used as a component of a power conversion device. The manufacturing method of the reactor of this invention can be utilized for manufacture of the above-mentioned reactor.

1A, 1B Reactor 2A, 2B Coil 2a, 2b Winding part 2j Connection part 2w Winding 3A, 3B Magnetic core 3g Gap part 31, 31a, 31b Inner core part 32A, 32B Outer core part 32a, 32b Individual end part 32c Connection Ends 32s ₁ , 32s ₂ Individual outer peripheral parts 32s Integrated outer peripheral parts 5A, 5B Insulating intervening parts 50α, 50β, 50γ, 50δ Division material 51 Cylindrical part 52 Frame plate part 52h Opening part 6 Heat radiation member

Claims (12)

1. Coils,
   A magnetic core disposed inside and outside the coil to form a closed magnetic circuit,
   The magnetic core is an integral molded body composed of a composite material containing soft magnetic powder and resin,
   The said coil is a reactor provided with the exposed area | region where at least one part of the outer peripheral surface was exposed without being covered with the said magnetic core.
2. The reactor according to claim 1, wherein the exposed region includes an installation surface of the coil.
3. The magnetic core includes an inner core portion disposed in the coil and an outer core portion in which the coil is not disposed,
   The reactor of Claim 1 or Claim 2 provided with the insulation interposition part interposed between the said coil and the said inner core part.
4. The magnetic core includes an inner core portion disposed in the coil and an outer core portion in which the coil is not disposed,
   The reactor according to any one of claims 1 to 3, wherein the outer core portion includes a protruding portion whose outer peripheral surface protrudes from an outer peripheral surface of the inner core portion.
5. The reactor according to any one of claims 1 to 4, further comprising a heat dissipating member disposed in the exposed region.
6. The reactor according to any one of claims 1 to 5, wherein the coil includes a heat-sealing resin portion that joins adjacent turns.
7. A heat dissipating member disposed in the exposed region;
   The said coil is a reactor of any one of Claims 1-6 provided with the heat sealing | fusion resin part which joins the said heat radiating member.
8. The said magnetic core is provided with the inner core part arrange | positioned in the said coil, the outer core part in which the said coil is not arrange | positioned, and the gap part provided in the said outer core part. The reactor described in the item.
9. The reactor according to any one of claims 1 to 8, wherein a content of the soft magnetic powder in the composite material is 30% by volume or more and 80% by volume or less.
10. A reactor manufacturing method for manufacturing a reactor comprising a coil and a magnetic core disposed inside and outside the coil to form a closed magnetic path,
    The reactor is the reactor according to any one of claims 1 to 9,
    A method for manufacturing a reactor, comprising a molding step of forming the integrally molded body by injection molding.
11. Assembling the insulating interposition part provided with the cylindrical part and the coil, and preparing a braided covering the inner peripheral surface of the coil with the cylindrical part,
    The method for manufacturing a reactor according to claim 10, wherein in the molding step, the cylindrical portion is filled with the composite material.
12. As the coil, prepare the one in which adjacent turns are joined by heat-sealing resin,
    The method of manufacturing a reactor according to claim 10, wherein the composite material is filled in the prepared coil in the forming step.

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