Apparatus and method for manufacturing a reactor
By using a design where the inner flow path is wider than the outer flow path during reactor manufacturing and by setting a core support pin in the mold, the problem of core cracking under resin pressure was solved, and stable molding of the reactor was achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- TOYOTA JIDOSHA KK
- Filing Date
- 2022-11-17
- Publication Date
- 2026-06-02
AI Technical Summary
In the prior art, the reactor core is prone to breakage during molding because the resin pressure cannot be effectively supported.
During the manufacturing process of reactors, core support pins are set in the mold to ensure pressure contact between the core and the resin. The inner flow path is wider than the outer flow path. The core support pins support the core during molding to prevent deformation and breakage.
This effectively prevents the core from cracking due to resin pressure during the molding process, thus improving the manufacturing reliability and success rate of the reactor.
Smart Images
Figure CN116153648B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to an apparatus and method for manufacturing reactors. Background Technology
[0002] Japanese Patent Application Publication No. 2013-149841 discloses a method for manufacturing a reactor that includes a primary molding process and a secondary molding process. According to the technology described in Japanese Patent Application Publication No. 2013-149841, a common mold can be used for both primary and secondary molding. Summary of the Invention
[0003] In the secondary molding process, when the resin preferentially enters the outer periphery of the core, it cannot support the core relative to the resin pressure, thus generating high stress in the core and causing it to crack.
[0004] The present invention was made to solve such problems, and its object is to provide a manufacturing apparatus and method for a reactor that can prevent core breakage due to resin pressure during molding.
[0005] The reactor manufacturing apparatus in this embodiment is a reactor manufacturing apparatus having a core, and it includes a mold having a cavity for accommodating the core.
[0006] The aforementioned mold includes a core support pin, which contacts the aforementioned core and supports the core relative to the resin pressure during molding.
[0007] The resin flow path during molding includes an inner flow path through the inner side of the aforementioned core and an outer flow path through the outer side of the aforementioned core.
[0008] The aforementioned core support pin is disposed at a position where the width of the aforementioned inner flow path is wider than the width of the aforementioned outer flow path.
[0009] The reactor manufacturing method in this embodiment is a method for manufacturing a reactor having a core, which includes the step of molding a molded article using a mold having a mold cavity that accommodates the aforementioned core.
[0010] The aforementioned mold includes a core support pin, which contacts the aforementioned core and supports the core relative to the resin pressure during molding.
[0011] The resin flow path in the molding process includes an inner flow path through the inner side of the aforementioned core and an outer flow path through the outer side of the aforementioned core.
[0012] The aforementioned core support pin is disposed at a position where the width of the aforementioned inner flow path is wider than the width of the aforementioned outer flow path.
[0013] According to the present invention, an apparatus and a method for manufacturing a reactor are provided that can prevent core breakage due to resin pressure during molding.
[0014] The above and other objects, features and advantages of the present invention will become more fully understood from the following detailed description and the accompanying drawings, which are for illustrative purposes only, and therefore should not be regarded as limiting the invention. Attached Figure Description
[0015] Figure 1 This is a schematic top view showing an outline of the mold involved in the related technology.
[0016] Figure 2 This is a schematic top view showing the structure of the core.
[0017] Figure 3 It is a diagram used to illustrate the dimensional relationship between the inner and outer flow paths of a mold involved in the related technology.
[0018] Figure 4 This is a diagram used to illustrate three modes of core rupture in the manufacturing apparatus involved in the related technology.
[0019] Figure 5 This is a schematic top view showing a mold of the manufacturing apparatus according to Embodiment 1.
[0020] Figure 6 This is a diagram used to illustrate the dimensional relationship between the inner and outer flow paths of the mold according to Embodiment 1.
[0021] Figure 7 This is a diagram illustrating the preferred dimensional relationships of the flow paths of the mold according to Embodiment 1.
[0022] Figure 8 This is a diagram illustrating the preferred dimensional relationships of the flow paths of the mold according to Embodiment 1.
[0023] Figure 9 This is a diagram illustrating the preferred dimensional relationships of the flow paths of the mold according to Embodiment 1. Detailed Implementation
[0024] Discussion of implementation methods
[0025] First, the research conducted by the inventors of this invention will be explained. Figure 1This is a schematic top view showing the outline of the mold 200 of the related manufacturing apparatus. The related manufacturing apparatus is a manufacturing apparatus for a reactor having a core. Furthermore, the related manufacturing apparatus may also include an opening and closing device (not shown) for the mold 200 or a resin injection device (not shown). A coil molded part 20 with a core 10 and molded with resin is inserted into the mold 200. Reference numeral R1 indicates the resin present in the coil molded part 20. Then, resin is injected around the core 10 and the coil molded part 20 for insert molding. During the molding process, holes h are also formed as insertion holes for bolts, etc. Figure 1 This indicates the state inside the mold 200 during the embedding and molding process.
[0026] exist Figure 1 For clarity, a three-dimensional Cartesian coordinate system (XYZ) is shown. Furthermore, the Z-direction is the vertical direction. Therefore, the Z-direction represents the height direction. For example, resin is injected into the negative Z-axis direction.
[0027] The mold 200 has a cavity for receiving the core 10. A pair of E-shaped cores 10 are inserted into the mold cavity, for example. The core 10 can be a sintered product formed by sintering pressed powder.
[0028] Figure 2 This is a schematic top view showing the structure of core 10. Core 10 includes a base core 11, a middle core 12, and outer cores 13a and 13b. Hereinafter, without distinguishing between outer cores 13a and 13b, they will sometimes be simply referred to as outer core 13. The middle core 12 and outer core 13 project from the base core 11 in the same direction. Figure 2 In the diagram, the X direction is the extension direction of the base core 11, and the Y direction is the extension direction of the middle lead core 12 and the outer lead core 13. A coil molded part 20 molded with resin is assembled in the middle lead core 12.
[0029] The base core 11 has a connecting portion 111a that connects the middle core 12 and the outer core 13a, and a connecting portion 111b that connects the middle core 12 and the outer core 13b. Hereinafter, without distinguishing between the connecting portions 111a and 111b, they will sometimes be referred to simply as the connecting portion 111.
[0030] The width (e.g., length in the X direction) of the outer cores 13a and 13b is narrower than the width of the middle core 12. In the case of manufacturing smaller reactors, the outer core 13 becomes thinner, and there is a possibility that the outer core 13 may break during molding.
[0031] return Figure 1Continuing the explanation, the resin flow path during molding includes inner flow paths 31a and 31b passing through the interior of core 10, outer flow path 32 passing through the exterior of core 10, flow path 33 passing through the interior of coil molding 20, and flow path 34 passing between the two cores 10. Hereinafter, without distinguishing between inner flow paths 31a and 31b, they will sometimes be simply referred to as inner flow path 31. Furthermore, without distinguishing between inner flow path 31, outer flow path 32, flow path 33, and flow path 34, they will sometimes be simply referred to as flow path 30. In the relevant mold 200, resin is preferentially injected into outer flow path 32. Therefore, there is a problem that core 10 may crack due to pressure applied from the outside to the inside as indicated by the arrow.
[0032] Figure 3 A schematic diagram showing the dimensional relationship between the outer flow path 32 and the inner flow path 31a in the mold 200 is provided. In the mold 200, the width W1 of the outer flow path 32 in the X direction is wider than the width W2 of the inner flow path 31a in the X direction. In this case, the outer core 13a of the core 10 is pressurized in the direction indicated by the right arrow. Similarly, the width of the outer flow path 32 in the Y direction is also wider than the width of the inner flow path 31a in the Y direction. Therefore, the base core 11 of the core 10 is pressurized in the direction indicated by the down arrow. The mold 200 lacks a mechanism to support the core 10 relative to resin pressure, thus there is a possibility of high stress and breakage in the core 10.
[0033] In order to prevent the core 10 from breaking, the inventors explored the relationship between the dimensions of each flow path 30 and the breakage mode of the core 10. Figure 4 This is a schematic diagram showing three fracture modes of core 10. Mode 1 occurs when resin is first filled from the outer flow path 32. In mode 1, as indicated by the arrow, the outer core 13 is pressurized along the X direction, generating high stress at location X1. Mode 1 occurs because there is no support mechanism on the inner side of the outer core 13.
[0034] Mode 2 also occurs when resin is first filled from the outer flow path 32. In Mode 2, as indicated by the arrow, the substrate core 11 is pressurized along the Y direction, generating high stress at location X2. Mode 2 occurs because there is no support mechanism inside the substrate core 11.
[0035] Mode 3 occurs when resin is first filled from the upper side of core 10. In mode 3, as indicated by the arrow, core 10 is pressed downwards, generating high stress at location X3. Mode 3 occurs because there is no support mechanism on the lower side of core 10 (e.g., the negative Z-axis side).
[0036] Based on the above discussion, the inventors of this invention conceived of the technical solutions involved in the embodiments. The invention will now be described through embodiments of the technical solutions, but the technical solutions in the claims are not limited to the following embodiments. Furthermore, all the structures described in the embodiments are not necessarily essential means of solving the problem.
[0037] Implementation Method 1
[0038] The manufacturing apparatus according to Embodiment 1 will now be described with reference to the accompanying drawings. Figure 5 This is a schematic top view showing an outline of the mold 100 of the manufacturing apparatus according to Embodiment 1. Furthermore, the following description focuses on the differences between the mold 200 of the related manufacturing apparatus described above.
[0039] The mold 100 includes core support pins 110a, 110b, 110c, 110d, 110e, 110f, and 110g. Hereinafter, without distinguishing between core support pins 110a, 110b, 110c, 110d, 110e, 110f, and 110g, they will sometimes be simply referred to as core support pin 110. Since the resin does not flow in the portion in contact with the core support pin 110, a window corresponding to the core support pin 110 is formed in the molded article.
[0040] Core support pin 110 contacts core 10 and supports core 10 relative to the resin pressure during molding. Core support pins 110a, 110b, 110c, and 110d support outer core 13 relative to the resin pressure during molding, as indicated by arrows in the ±X direction. Core support pins 110e, 110f, and 110g support base core 11 relative to the resin pressure during molding, as indicated by arrows in the ±Y direction. Downward arrows indicate the cases where resin pressure is applied from both inner flow paths 31. Core support pins 110e and 110f support the connecting portion 111 included in base core 11.
[0041] Core support pins 110a, 110b, 110c, 110d, 110e, and 110f are positioned where the width of the inner flow path 31 is wider than the width of the outer flow path 32. Additionally, some core support pins 110 (e.g., core support pin 110e) may be positioned in other locations.
[0042] Figure 6 This is a schematic diagram showing the dimensional relationship between the outer flow path 32 and the inner flow path 31a in the mold 100. The outer flow path 32 includes the flow path outside the outer lead core 13a. The inner flow path 31a includes the flow path of the gap between the coil molded part 20 and the outer lead core 13a.
[0043] In mold 100, the width W2 of the inner flow path 31a in the X direction is wider than the width W1 of the outer flow path 32 in the X direction. In other words, the width of the aforementioned gap is wider than the width of the flow path on the outer side of the outer core 13a. Under these circumstances, the outer core 13a of the core 10 is pressurized in the direction indicated by the left arrow. The core support pin 110a supports the outer core 13a with pressure relative to the direction of the left arrow, preventing deformation of the outer core 13a.
[0044] Similarly, the width of the inner flow path 31a in the Y direction is wider than the width of the outer flow path 32 in the Y direction. Therefore, the base core 11 of the core 10 is pressurized in the direction indicated by the upper arrow. The core support pin 110f supports the base core 11 with pressure relative to the direction of the upper arrow, preventing deformation of the base core 11.
[0045] The mold 100 is designed such that the width of the inner flow path 31 is wider than the width of the outer flow path 32, which can prevent the core 10 from deforming inward and breaking. In addition, the core 10 is supported from the outside by the core support pin 110, which can prevent the core 10 from deforming outward and breaking. Therefore, the manufacturing apparatus according to Embodiment 1 can prevent the core 10 from breaking due to resin pressure during molding.
[0046] Next, refer to Figures 7 to 9 This explains the preferred dimensional relationships of each flow path 30. Figures 7 to 9 This is a diagram used to illustrate the preferred dimensional relationships of each flow path 30. Furthermore, in Figures 7 to 9 The illustration of the core support pin 110 is omitted in the text. Figure 7 Reference numeral A in the attached figure indicates the width of the inner flow path 31 in the X direction. Figure 7 The reference numeral B in the attached figure indicates the width B of the outer flow path 32 in the X direction. Figure 8 The reference numeral C in the attached figure indicates the width of the inner flow path 31 in the Y direction. Figure 8 The reference numeral D in the attached figure indicates the width of the outer flow path 32 in the Y direction. Figure 9 The reference numeral H in the attached figure indicates the width of the flow path 34 described above. The inventors have discovered that by satisfying the first to third dimensional relationships below, it is possible to prevent the breakage of the above-described modes 1 to 3.
[0047] Reference Figure 7 The first dimensional relationship satisfies A > B and 0.5 ≤ B ≤ 2 (in mm). Based on the relationship with Mode 1 above, the width of the inner flow path 31 in the X direction is set to be wider than the width of the outer flow path 32 in the X direction. The width of the outer flow path 32 in the X direction can be selected from a range of 0.5 mm or more and 2 mm or less.
[0048] Reference Figure 8The second dimensional relationship satisfies C > D and 0.5 ≤ D ≤ 2 (unit: mm). Based on the relationship with Mode 2 described above, the width of the inner flow path 31 in the Y direction needs to be set wider than the width of the outer flow path 32 in the Y direction. Furthermore, based on the relationship with Mode 3 described above, the width of the outer flow path 32 in the Y direction needs to be appropriately set.
[0049] Reference Figure 9 The third dimensional relationship satisfies 0.4 ≤ H ≤ 2 (in mm), and at least one of the outer cores 13a and outer cores 13b is in contact with each other. Based on the relationships in modes 2 and 3 above, the width of the flow path 34 needs to be selected from a range of 0.4 mm to 2 mm.
[0050] In the manufacturing apparatus according to Embodiment 1, by making the size of the inner flow path wider than the size of the outer flow path, resin is first injected from the inside of the core 10, and the core, which bears the resin pressure, is set in a pin support of the mold. Therefore, in the manufacturing apparatus according to Embodiment 1, by suppressing the deformation of the core, the stress inside the core is reduced, and the core 10 can be prevented from cracking.
[0051] Furthermore, the present invention is not limited to the above-described embodiments, and appropriate modifications may be made without departing from the spirit of the invention.
[0052] Based on the invention described herein, it will be apparent that embodiments of the invention can be varied in many ways. Such variations should not be considered a departure from the spirit and scope of the disclosure, and all such modifications that will be apparent to those skilled in the art are included within the scope of the appended claims.
Claims
1. An apparatus for manufacturing a reactor with a core, A mold having a cavity for receiving the core. The mold includes a core support pin that contacts the core and supports the core relative to the resin pressure during molding. The resin flow path during molding includes an inner flow path through the inside of the core and an outer flow path through the outside of the core. The core support pin is positioned where the width of the inner flow path is wider than the width of the outer flow path. The manufacturing apparatus is a reactor manufacturing apparatus having a pair of E-shaped cores. Each E-shaped core has an outer core and a middle core protruding in the same direction from the base core. The width of the outer core is smaller than the width of the middle core. The core support pin supports the outer foot core with resin pressure in a direction orthogonal to the direction in which the outer foot core protrudes from the base core.
2. The reactor manufacturing apparatus according to claim 1, characterized in that, A resin-molded coil is assembled in the central core. The inner flow path includes a flow path through the gap between the coil molding and the outer lead core. The outer flow path includes the flow path outside the outer foot core. The width of the gap is wider than the width of the flow path on the outer side of the outer foot core.
3. The reactor manufacturing apparatus according to claim 1 or 2, characterized in that, The base core has a connecting portion that connects the middle lead core and the outer lead core. The core support pin supports the connecting part.
4. A method for manufacturing a reactor with a core, This includes the step of molding an article using a mold having a cavity that houses the core. The mold includes a core support pin that contacts the core and supports the core relative to the resin pressure during molding. The resin flow path in the molding process includes an inner flow path through the inside of the core and an outer flow path through the outside of the core. The core support pin is positioned where the width of the inner flow path is wider than the width of the outer flow path. The manufacturing method is a method for manufacturing a reactor having a pair of E-shaped cores. Each E-shaped core has an outer core and a middle core protruding in the same direction from the base core. The width of the outer core is smaller than the width of the middle core. The core support pin supports the outer foot core with resin pressure in a direction orthogonal to the direction in which the outer foot core protrudes from the base core.