Core module and method for manufacturing the same

Abstract

This invention provides a core module that integrates a magnetic core and busbars without using resin molding, thereby achieving miniaturization. [Solution] The device comprises a magnetic core (4), a core case (8) that houses the magnetic core and includes a hollow section (hollow support section 32), a first busbar (6-1) and a second busbar (6-2) with a conductive member (12) integrated into an insulating section (14), and locking sections (26-11, 26-12, 26-21, 26-22) formed on the insulating section of either the first busbar or the second busbar that is inserted into the hollow section, for locking the first busbar or the second busbar.

Description

[Technical Field]

[0001] The present disclosure relates to a core module including a magnetic core and a method for manufacturing the same. [Background Art]

[0002] The core module is an electronic component used, for example, to remove high-frequency noise caused by current flowing in a line included in a power supply device or the like, and includes a bus bar and a magnetic core surrounding the bus bar.

[0003] Regarding this core module, a technique of integrating a plurality of bus bars and a magnetic core with a molding member is known (for example, Patent Document 1). [Prior Art Literature] [Patent Documents]

[0004] [Patent Document 1] Japanese Unexamined Patent Application Publication No. 2016-24939 [Summary of the Invention] [Problem to be Solved by the Invention]

[0005] In a core module in which a plurality of bus bars and a magnetic core are integrated by resin molding, since a heated resin material is pressurized and poured into a mold, if the bus bar and the magnetic core receive molding stress in a state where they are not integrated, positional deviation occurs between the bus bar and the magnetic core, which causes a problem of deteriorating the electrical characteristics of the core module.

[0006] Furthermore, resin molding requires a complex mold for integrating the bus bars and the magnetic core, and there is also a problem that the thickness of the resin layer formed by resin molding leads to an increase in size of the core module.

[0007] Furthermore, after molding, the resin layer shrinks during cooling, and this shrinkage force acts as excessive stress on the magnetic core and busbars, potentially damaging the core module or degrading its electrical properties. Additionally, it is difficult to visually inspect the inside of the core module covered by the resin layer, making it challenging to detect defects such as damage or misalignment of busbars in the resin mold.

[0008] Such problems are not disclosed or suggested, and the configuration disclosed in Patent Document 1 cannot solve these problems.

[0009] Therefore, the purpose of this disclosure is to provide a core module that integrates a magnetic core and busbars without using resin molds, thereby achieving miniaturization. [Means for solving the problem]

[0010] To achieve the above objective, according to one aspect of the core module of this disclosure, the core module comprises a magnetic core, a core case including a hollow portion and housing the magnetic core, a first busbar and a second busbar with a conductive member integrated into the insulating portion, and a locking portion formed on the insulating portion of either the first busbar or the second busbar which is inserted into the hollow portion, for locking the first busbar or the second busbar.

[0011] In this core module, the first busbar and the second busbar may be provided with rail sections, and these rail sections may guide the locking sections of the first busbar or the second busbar to the locked state of the first busbar and the second busbar.

[0012] In this core module, the hollow portion of the core case may be provided with grooves for engaging one or both of the first busbar or the second busbar.

[0013] In this core module, the first busbar and the second busbar may have bent portions, and these bent portions may be located on the outside of the core case.

[0014] To achieve the above objective, according to one aspect of the manufacturing method of the core module of this disclosure, the method includes the steps of: housing a magnetic core in a core case including a hollow portion; inserting a first busbar and a second busbar, each having a conductor member integrated into an insulating portion, into the hollow portion; and locking the first busbar or the second busbar to a locking portion formed on the insulating portion of either the first busbar or the second busbar.

[0015] The manufacturing method of this core module may include the step of inserting the first busbar from one side of the hollow portion, inserting the second busbar from the other side of the hollow portion, and locking the first busbar and the second busbar together within the hollow portion. [Effects of the Invention]

[0016] According to this disclosure, one of the following effects can be obtained: (1) A core module can be provided that integrates a magnetic core, a core case, and multiple busbars without using a resin mold.

[0017] (2) This prevents misalignment of the magnetic core and busbars due to resin molding, thus preventing deterioration of electrical characteristics and providing a highly reliable core module.

[0018] (3) The magnetic core, busbars, and integration of multiple busbars are not subjected to stress from heating or resin molding, and the size increase due to the insulating layer is prevented, allowing the core module to be miniaturized. [Brief explanation of the drawing]

[0019] [Figure 1] Figure 1 is an exploded perspective view showing a core module according to one embodiment. [Figure 2] Figure 2 is a perspective view showing the core module. [Figure 3]3A is a cross-sectional view taken along line IIIA-IIIA in FIG. 2, and 3B is a cross-sectional view taken along line IIIB-IIIB in FIG. 3A. [Figure 4] 4A is a cross-sectional view showing a state before locking of the first bus bar and the second bus bar, 4B is a cross-sectional view showing a state before locking of the first bus bar and the second bus bar, and 4C is a cross-sectional view showing a locked state of the first bus bar and the second bus bar. [Figure 5] FIG. 5 is a perspective view showing a modified example of the first bus bar and the second bus bar. DESCRIPTION OF EMBODIMENTS

[0020] FIG. 1 is an exploded view showing a core module according to an embodiment of the present disclosure. The configuration shown in FIG. 1 is an example, and the core module of the present disclosure is not limited to such a configuration.

[0021] The core module 2 includes a magnetic core 4, a first bus bar 6-1, a second bus bar 6-2, and a core case 8.

[0022] <Magnetic Core 4> The magnetic core 4 is formed of a magnetic material into an annular shape, and includes a core hollow portion 10 formed of a circular hole. It is preferable that the outer diameter of the magnetic core 4 and the inner diameter of the core hollow portion 10 are concentric.

[0023] <First Bus Bar 6-1> The first bus bar 6-1 is formed of a conductor member 12 and an insulating portion 14, the conductor member 12 is integrated with the insulating portion 14, and the insulating portion 14 side is provided with a flat plate portion 16-1 and a bent portion 18-1. The conductor member 12 is formed of a highly conductive metal material, for example, copper. Both end portions of the conductor member 12 are provided with terminal portions 20-11 and 20-12 on the first bus bar 6-1 side. A through hole 22 is formed in each of the terminal portions 20-11 and 20-12.

[0024] The insulating portion 14 is formed of a highly insulating resin, such as PA (polyamide) or PPS (polyphenylene sulfide). For integration such as locking the core case 8, the first busbar 6-1, and the second busbar 6-2, it is preferable that the insulating portion 14 has elasticity. The conductive member 12 is insert-molded into this insulating portion 14.

[0025] Terminal portion 20-11 is formed on the extension of the flat plate portion 16-1. Terminal portion 20-12 is formed in the opposite direction to terminal portion 20-11, and its horizontal and vertical position is displaced by the bent portion 18-1. Terminal portion 20-12 is set higher than terminal portion 20-11 by a thickness exceeding that of the flat plate portion 16-1, and is set at a position displaced by a width exceeding the processing allowance of terminal portion 20-11. As a result, terminal portion 20-11 of the first busbar 6-1 and terminal portion 20-22 of the second busbar 6-2 can be placed on a common horizontal plane, and terminal portion 20-12 of the first busbar 6-1 and terminal portion 20-21 of the second busbar 6-2 can be placed on a common horizontal plane.

[0026] A pair of first rail sections 24-11 and 24-12 are formed on the flat plate section 16-1. The first rail sections 24-11 and 24-12 have convex sections of the same height that are formed in a straight and parallel manner. If the rail width of the first rail sections 24-11 and 24-12 is W1, and the rail width of the second rail sections 24-21 and 24-22 of the second busbar 6-2 is W2, then the rail width W1 is set to be wider than the rail width W2 (i.e., W1 > W2), enabling locking between the two.

[0027] Between the first rail sections 24-11 and 24-12 of the flat plate section 16-1, a first locking section 26-11 is formed on the side of the bent section 18-1, and a second locking section 26-12 and a guide groove 28-1 are formed on the side of the terminal section 20-11. The first locking section 26-11 is a convex section with a triangular cross-section, having a stopper surface that rises steeply on the side of the bent section 18-1 and a guide surface that rises gently on the other side. The second locking section 26-12 is a recess for locking the first locking section 26-21 of the second bus bar 6-2. The guide groove 28-1 is a groove that guides the first locking section 26-21 of the second bus bar 6-2, and is formed to be shallower than the second locking section 26-12.

[0028] <Second bus bar 6-2> In Figure 1, the second busbar 6-2 is shown with the rail side facing upwards, similar to the first busbar 6-1. This second busbar 6-2 is formed of a conductor member 12 and an insulating part 14, similar to the first busbar 6-1, and includes a flat plate part 16-2 and a bent part 18-2. Terminal parts 20-21 and 20-22 are provided at both ends of the conductor member 12. Through holes 22 are also formed in the terminal parts 20-21 and 20-22, similar to the first busbar 6-1.

[0029] Terminal portions 20-21 are formed on the extension of the flat plate portion 16-2, similar to the first busbar 6-1. Terminal portions 20-22 are formed in the opposite direction to terminal portions 20-21, and their horizontal and vertical positions are displaced by the bent portion 18-2. The height position of terminal portion 20-22 is higher than terminal portion 20-21 by a thickness exceeding that of the flat plate portion 16-2, and is displaced by a width exceeding the processing allowance of terminal portion 20-21.

[0030] A pair of second rail sections 24-21 and 24-22 are formed on the flat plate section 16-2. The second rail sections 24-21 and 24-22 have convex sections of the same height that are formed linearly and parallel to each other, similar to the first rail sections 24-11 and 24-12 of the first bus bar 6-1.

[0031] Between the second rail sections 24-21 and 24-22 of the flat plate section 16-2, a first locking section 26-21 is formed on the bent section 18-2 side, and a second locking section 26-22 and a guide groove 28-2 are formed on the terminal section 20-21 side, similar to the first bus bar 6-1. The first locking section 26-21 is a triangular cross-section protrusion having a stopper surface that rises steeply on the bent section 18-2 side and a guide surface that rises gently on the other side. The second locking section 26-22 is a recess for fitting the first locking section 26-11 of the first bus bar 6-1. The guide groove 28-2 is a groove that guides the first locking section 26-11 of the first bus bar 6-1, and is formed to be shallower than the recess of the second locking section 26-22.

[0032] <Core Case 8> The core case 8 comprises a case body 8-1 and a lid 8-2, and is a molded body integrally processed from insulating resin, similar to the insulating parts 14 of the first busbar 6-1 and the second busbar 6-2.

[0033] The case body 8-1 includes a cylindrical core housing 30 for housing the magnetic core 4, and a cylindrical hollow support portion 32 is formed in the center of the core housing 30. The hollow support portion 32 is an example of a hollow portion into which either or both of the first bus bar 6-1 or the second bus bar 6-2 are inserted. The inner diameter of the core housing 30 is concentric with the outer diameter of the magnetic core 4 and is formed to be slightly larger in diameter than the outer diameter of the magnetic core 4. The outer diameter of the hollow support portion 32 is concentric with the core hollow portion 10 and is formed to be slightly smaller in diameter than the inner diameter of the core hollow portion 10.

[0034] The hollow support portion 32 has a first groove 34-1 for supporting the flat plate portion 16-1 of the first bus bar 6-1 and a second groove 34-2 for supporting the flat plate portion 16-2 of the second bus bar 6-2, and also has multiple air cooling channels 36 formed in the XY axis direction.

[0035] A small diameter section 38 is formed on the outer edge of the opening of the case body 8-1 for fitting the lid 8-2, and a fitting recess 42 is also formed on the open end edge of the hollow support section 32 for fitting the opening 40 of the lid 8-2. The opening 40 of the lid 8-2 is smaller in diameter than the outer diameter of the hollow support section 32 and is sized to allow the first bus bar 6-1 and the second bus bar 6-2 to be pulled out.

[0036] Base portions 44 are formed on the case body portion 8-1 and the lid portion 8-2, and a metal collar 46 is attached to the base portion 44 on the case body portion 8-1 side by an insert.

[0037] <Core Module 2> As shown in Figure 2, the core module 2 is assembled and integrated from a magnetic core 4, a first busbar 6-1, a second busbar 6-2, and a core case 8.

[0038] The core housing section 30 of the case body 8-1, which houses the magnetic core 4 (Figure 1), is closed by the lid 8-2. The first bus bar 6-1 is inserted into the hollow support section 32 through the opening 40 of the lid 8-2, and the terminal section 20-11 is pulled out from the rear side of the case body 8-1. The second bus bar 6-2 is inserted into the hollow support section 32 from the rear side of the case body 8-1 and pulled out through the opening 40. In this state, the core module 2 is integrated, consisting of the magnetic core 4, the first bus bar 6-1, the second bus bar 6-2, and the core case 8.

[0039] The bent portion 18-1 of the first bus bar 6-1 is positioned on the lid portion 8-2 side of the core case 8, and the bent portion 18-2 of the second bus bar 6-2 is positioned on the case body portion 8-1 side of the core case 8, and the core case 8 is held between the bent portion 18-1 of the first bus bar 6-1 and the bent portion 18-2 of the second bus bar 6-2, which are joined together inside the core case 8. In other words, the core case 8 is held between the bent portions 18-1 and 18-2 in close contact with them.

[0040] <Support structure for magnetic core 4> Figure 3A shows the section along line IIIA-IIIA in Figure 2, and Figure 3B shows the section along line IIIB-IIIB in Figure 3A.

[0041] The magnetic core 4 is supported by the hollow support portion 32 inserted into the hollow core portion 10, and is housed in the core storage portion 30 of the case body portion 8-1, and is fixedly supported by the core case 8. The case body portion 8-1 housing the magnetic core 4 is covered with a lid portion 8-2, and the core case 8 is kept in a sealed state. Therefore, the magnetic core 4 is protected by the core case 8.

[0042] <Locking structure for the first busbar 6-1 and the second busbar 6-2> In the hollow support section 32, the second rail sections 24-21 and 24-22 of the second busbar 6-2 are superimposed on the upper side of the first rail sections 24-11 and 24-12 of the first busbar 6-1, and the first busbar 6-1 and the second busbar 6-2 are positioned by the locking of these first rail sections 24-11 and 24-12 and the second rail sections 24-21 and 24-22. In other words, the second rail sections 24-21 and 24-22 of the second busbar 6-2, which have a rail width W2, are positioned within the rail width W1 of the first rail sections 24-11 and 24-12 of the first busbar 6-1.

[0043] <Locking structure for the first busbar 6-1 and the second busbar 6-2 by the first groove 34-1 and the second groove 34-2> In the hollow support section 32, the flat plate portion 16-1 of the first busbar 6-1 is locked into the first groove 34-1, and the flat plate portion 16-2 of the second busbar 6-2 is locked into the second groove 34-2. Therefore, the stacked first busbar 6-1 and second busbar 6-2 are firmly locked and supported within the hollow support section 32.

[0044] <Locking structure for the first busbar 6-1 and the second busbar 6-2> In the hollow support section 32, as shown in Figure 3B, the first locking portion 26-11 of the first bus bar 6-1 and the second locking portion 26-22 of the second bus bar 6-2 are locked together, and the second locking portion 26-12 of the first bus bar 6-1 and the first locking portion 26-21 of the second bus bar 6-2 are locked together. Through these lockings, the first bus bar 6-1 and the second bus bar 6-2 are locked together and integrated.

[0045] <Manufacturing process for Core Module 2> The manufacturing process for the core module 2 is an example of a manufacturing method for the core module 2 of this disclosure. This manufacturing process for the core module 2 includes a process for housing the magnetic core 4, a process for locking the first bus bar 6-1 and the second bus bar 6-2, and the like.

[0046] Storage process for magnetic core 4: The hollow support portion 32 is inserted into the hollow core portion 10 of the magnetic core 4, and the magnetic core 4 is housed in the case body portion 8-1. The lid portion 8-2 is placed over the case body portion 8-1, and the core case 8 is closed.

[0047] Locking process for the first busbar 6-1 and the second busbar 6-2: Figure 4A shows the manufacturing process of the core module 2, with the first busbar 6-1 and the second busbar 6-2 inserted into the hollow support section 32.

[0048] As shown in Figure 4A, after the magnetic core 4 is housed in the core case 8, the flat portion 16-1 of the first busbar 6-1 is inserted into the hollow support portion 32 from the rear side of the case body portion 8-1 of the core case 8. At this time, the flat portion 16-1 of the first busbar 6-1 is inserted into the first groove portion 34-1, thereby maintaining the first busbar 6-1 in the hollow support portion 32.

[0049] After inserting the first bus bar 6-1, the flat plate portion 16-2 of the second bus bar 6-2 is inserted through the opening 40 of the lid portion 8-2 of the core case 8. At this time, the flat plate portion 16-2 of the second bus bar 6-2 is inserted into the second groove portion 34-2, and the second rail portions 24-21 and 24-22 of the second bus bar 6-2 are engaged with the rail width W1 of the first rail portions 24-11 and 24-12 of the first bus bar 6-1 and slid in.

[0050] When the second bus bar 6-2 is pushed toward the first bus bar 6-1, as shown in Figure 4B, the first locking portion 26-21 of the second bus bar 6-2 overlaps with the guide groove 28-1 of the first bus bar 6-1, and at this time, the first locking portion 26-11 of the first bus bar 6-1 enters and overlaps with the guide groove 28-2 of the second bus bar 6-2.

[0051] When the second bus bar 6-2 is pushed to its end point (i.e., the point where the bent portion 18-2 contacts the back of the core case 8), as shown in Figure 4C, the first locking portion 26-11 of the first bus bar 6-1 and the second locking portion 26-22 of the second bus bar 6-2 are locked together, and at this time, the second locking portion 26-12 of the first bus bar 6-1 and the first locking portion 26-21 of the second bus bar 6-2 are locked together. These lockings lock the first bus bar 6-1 and the second bus bar 6-2 together. This locked state is maintained between the first groove 34-1 and the second groove 34-2 of the hollow support portion 32.

[0052] The insertion amount of the first bus bar 6-1 into the hollow support portion 32 of the case body portion 8-1 is restricted by the bent portion 18-1, and the insertion amount of the second bus bar 6-2 is restricted by the bent portion 18-2, so that the arrangement of the flat portion 16-1 of the first bus bar 6-1 and the flat portion 16-2 of the second bus bar 6-2 into the hollow support portion 32 or the magnetic core 4 is positioned at a predetermined location.

[0053] <Effects of one embodiment> According to the embodiment described above, one of the following effects can be obtained. (1) Locking structure of the first bus bar 6-1 and the second bus bar 6-2 By providing the first bus bar 6-1 with a first locking portion 26-11 and a second locking portion 26-12, and the second bus bar 6-2 with a first locking portion 26-21 and a second locking portion 26-22, the locking of the first locking portion 26-11 and the second locking portion 26-22, and simultaneously the locking of the second locking portion 26-12 and the first locking portion 26-21, maintains the locked state of the first bus bar 6-1 and the second bus bar 6-2 while they are inserted into the hollow support portion 32, thereby firmly fixing and supporting the first bus bar 6-1 and the second bus bar 6-2 in the hollow support portion 32.

[0054] (2) Locking structure of the first bus bar 6-1 and the second bus bar 6-2 by the first groove 34-1 and the second groove 34-2 The first busbar 6-1 and the second busbar 6-2, inserted into the hollow support portion 32, are positioned by being locked into the first groove portion 34-1 and the second groove portion 34-2, and can be firmly locked in a parallel state within the hollow support portion 32, thereby preventing displacement of the first busbar 6-1 and the second busbar 6-2.

[0055] (3) Locking structure of the first bus bar 6-1 and the second bus bar 6-2 by the first rail sections 24-11, 24-12 and the second rail sections 24-21, 24-22 The first busbar 6-1 and the second busbar 6-2, inserted into the hollow support section 32, are slidably maintained by the locking of the first rail sections 24-11, 24-12 and the second rail sections 24-21, 24-22, and can also be firmly locked in a parallel state within the hollow support section 32.

[0056] (4) Fixing structure of magnetic core 4 The hollow support portion 32 of the case body portion 8-1 is inserted into the hollow core portion 10 of the magnetic core 4, and the magnetic core 4 is housed in the core storage portion 30 of the case body portion 8-1, so that the magnetic core 4 can be firmly held inside the core case 8. In addition, the magnetic core 4 can be protected by the core case 8.

[0057] (5) Integrated structure of magnetic core 4, first busbar 6-1, second busbar 6-2 and core case 8 As previously described, by providing a locking structure with first locking parts 26-11, 26-21 and second locking parts 26-12, 26-22, a locking structure with first groove part 34-1 and second groove part 34-2, a locking structure with first rail parts 24-11, 24-12 and second rail parts 24-21, 24-22, and a fixing structure for the magnetic core 4, the magnetic core 4, the first bus bar 6-1, the second bus bar 6-2 and the core case 8 can be integrated, realizing a robust integrated structure.

[0058] (6) Restriction of the insertion amount of the first bus bar 6-1 and the second bus bar 6-2 by the bent portions 18-1 and 18-2 Since the insertion amount of the first busbar 6-1 and the second busbar 6-2 inserted into the hollow support portion 32 is restricted by the bent portions 18-1 and 18-2, the accuracy of the longitudinal insertion position of the first busbar 6-1 and the second busbar 6-2 can be improved. In other words, the fixing positions of the flat plate portions 16-1 and 16-2 with respect to the hollow support portion 32 can be kept constant, and the uniformity of electrical characteristics can be improved.

[0059] (7) Insulation of the first busbar 6-1 and the second busbar 6-2 Each conductor member 12 of the first busbar 6-1 and the second busbar 6-2 can be insulated by insert molding of the insulating portion 14.

[0060] (8) Air cooling of the first bus bar 6-1 and the second bus bar 6-2 in the hollow support section 32 The hollow support section 32 has an air cooling channel 36 that surrounds the first busbar 6-1 and the second busbar 6-2, allowing the first busbar 6-1 and the second busbar 6-2 to be air-cooled, thereby stabilizing their characteristics.

[0061] (9) Reduction of the number of parts This core module 2 consists of a magnetic core 4, a first busbar 6-1, a second busbar 6-2, and a core case 8. The core case 8 consists of a case body 8-1 and a lid 8-2, so the core module 2 can be realized with an extremely small number of parts.

[0062] (10) Miniaturization of Core Module 2 The core case 8 can be designed to the minimum size relative to the shapes of the magnetic core 4, the first busbar 6-1, and the second busbar 6-2, allowing for a smaller core module 2 compared to resin molding.

[0063] (11) Positional accuracy of the magnetic core 4, the first busbar 6-1 and the second busbar 6-2 Previously, when heated resin material was poured into a mold under pressure, and the busbars and magnetic core were subjected to molding stress while not integrated, positional misalignment occurred in the busbars and magnetic core, which degraded the electrical characteristics of the core module. However, in this core module 2, the magnetic core 4 is housed and positioned in the core case 8, and the first busbar 6-1 and second busbar 6-2 can be inserted into the hollow support portion 32 of the core case 8 and fixed in position, thus realizing a core module 2 with high positional accuracy and excellent electrical characteristics.

[0064] <Modified versions of the first busbar 6-1 and the second busbar 6-2> Figure 5 shows modified examples of the first busbar 6-1 and the second busbar 6-2. In these modified examples, the length of the flat sections 16-1 and 16-2 is extended by the width of the conductor member 12, and the bending width of the bent sections 18-1 and 18-2 is made smaller.

[0065] <Effects of variations> According to this modification, one of the following effects can be obtained: (1) The same effects as in the above embodiment can be obtained, and the width of the bent portions 18-1 and 18-2 can be reduced, making the core module 2 more compact.

[0066] (2) The conductor member 12 can be shortened, and desired electrical characteristics such as reduced electrical resistance can be achieved.

[0067] [Other embodiments] (1) Regarding the arrangement of the first busbar 6-1 and the second busbar 6-2, in one embodiment the first busbar 6-1 is placed on the lower side and the second busbar 6-2 is placed on the upper side of the first busbar 6-1, but the first busbar 6-1 may also be placed on the upper side of the second busbar 6-2.

[0068] (2) Regarding the setting and combination of rail widths W1 and W2 of the first rail sections 24-11 and 24-12 and the second rail sections 24-21 and 24-22, the rail width of the first rail sections 24-11 and 24-12 may be made smaller than the rail width of the second rail sections 24-21 and 24-22, or the rail widths of both may be made the same, and the formation positions of the two may be different so that they are locked together.

[0069] (3) Regarding the form of the first rail sections 24-11, 24-12 and the second rail sections 24-21, 24-22, in one embodiment each rail section is formed with a convex portion, but either one may be a convex portion or a concave portion, and they may be configured to slide by locking the concave and concave portions together.

[0070] (4) Regarding the orthogonal or non-parallel arrangement of the seating surface of the base portion 44 and the first bus bar 6-1 and the second bus bar 6-2, in one embodiment the first bus bar 6-1 and the second bus bar 6-2 are arranged parallel to the seating surface of the base portion 44, but the first bus bar 6-1 and the second bus bar 6-2 and the seating surface of the base portion 44 may be arranged orthogonally or non-parallel.

[0071] (5) Regarding the orthogonal or non-parallel arrangement of the seating surface of the base portion 44 and the terminal portions 20-11, 20-12, 20-21, and 20-22, in one embodiment the terminal portions 20-11, 20-12, 20-21, and 20-22 are arranged parallel to the seating surface of the base portion 44, but the terminal portions 20-11, 20-12, 20-21, and 20-22 and the seating surface of the base portion 44 may be arranged orthogonally or non-parallel.

[0072] (6) In the above embodiment, both the first busbar 6-1 and the second busbar 6-2 are provided with locking portions, but the locking portions may be formed on the insulating portion 14 of either the first busbar or the second busbar.

[0073] As explained above, the most preferred embodiments of this disclosure have been described, but this disclosure is not limited to the above description, and it goes without saying that various modifications and changes can be made by those skilled in the art based on the gist of the invention described in the claims or disclosed in the specification, and such modifications and changes are included in the scope of this disclosure. [Industrial applicability]

[0074] This disclosure makes it possible to realize a robust core module by integrating the magnetic core 4, the first busbar 6-1, the second busbar 6-2, and the core case 8 without using a resin mold. [Explanation of symbols]

[0075] 2 Core Modules 4 Magnetic core 6-1 First Bus Bar 6-2 Second Bus Bar 8-core case 8-1 Case body 8-2 Lid 10 Core hollow section 12 Conductor Members 14 Insulation 16-1, 16-2 Flat plate part 18-1, 18-2 Bending section 20-11, 20-12, 20-21, 20-22 terminal section 22 Throughpores 24-11, 24-12 First rail section 24-21, 24-22 Second rail section 26-11, 26-21 First locking part 26-12, 26-22 Second locking part 28-1, 28-2 Guide grooves 30 Core storage compartment 32 Hollow support part 34-1 First groove 34-2 Second groove 36 Air cooling channel 38 Small diameter section 40 openings 42 Fitting recess 44 Base 46 Metallic Colors

Claims

1. A magnetic core and A core case containing a hollow portion and housing the magnetic core, A first busbar and a second busbar with a conductor member integrated into the insulating portion, A locking portion is formed on the insulating portion of either the first busbar or the second busbar, which is inserted into the hollow portion, and locks the first busbar or the second busbar. A core module characterized by having the following features.

2. The core module according to claim 1, characterized in that the first busbar and the second busbar are provided with rail portions, and the rail portions guide the locking portions of the first busbar or the second busbar to the locked state of the first busbar and the second busbar.

3. The core module according to claim 1, characterized in that the hollow portion of the core case is provided with a groove for engaging one or both of the first busbar or the second busbar.

4. The core module according to claim 1, characterized in that the first busbar and the second busbar are provided with a bent portion, and the bent portion is located on the outside of the core case.

5. A process of housing a magnetic core in a core case including a hollow section, The process involves inserting a first busbar and a second busbar, each having a conductor member integrated into the insulating portion, into the hollow portion, and locking the first busbar or the second busbar to a locking portion formed on the insulating portion of either the first busbar or the second busbar, A method for manufacturing a core module, characterized by including the following:

6. The method for manufacturing a core module according to claim 5, characterized by including the step of inserting the first busbar from one side of the hollow portion, inserting the second busbar from the other side of the hollow portion, and locking the first busbar and the second busbar together within the hollow portion.

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