Apparatus and method for manufacturing a reactor

Abstract

Provided is a reactor manufacturing device and manufacturing method that can accommodate dimensional variations in a core and prevent deformation of the core caused by resin pressure during molding. The reactor manufacturing device is a reactor manufacturing device that includes a core. The manufacturing device includes a mold having a mold cavity that accommodates the core. The mold includes a plurality of pins that protrude into the mold cavity. When the core is disposed in the mold cavity, at least one of the plurality of pins is not fixed and each pin functions as a positioning pin. When the core is molded into a molded product, the pins are fixed and each pin functions as a core support pin that supports the core against resin pressure during molding.

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 Patent Document 1, a common mold can be used in both the primary and secondary molding processes. Summary of the Invention

[0003] However, the mold in the reactor manufacturing apparatus contains multiple locating pins for positioning the core. If the locating pins cannot withstand the resin pressure during molding, the core may break due to the resin pressure. On the other hand, if high pressure is applied to the locating pins to withstand the resin pressure, the core may break during positioning due to dimensional deviations.

[0004] The present invention was made to solve such problems, and its purpose is to provide a reactor manufacturing apparatus and manufacturing method that can take into account both the dimensional deviation of the absorber core and the deformation caused by the 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 has multiple pins protruding into the aforementioned mold cavity.

[0007] When the aforementioned core is placed in the aforementioned mold cavity, at least one of the aforementioned pins is not fixed, and each pin functions as a positioning pin.

[0008] During the molding process, at least one of the aforementioned pins is fixed, and each pin functions as a core support pin that supports the aforementioned core relative to the resin pressure during molding.

[0009] The method for manufacturing the reactor in this embodiment is a method for manufacturing a reactor having a core, including:

[0010] The step of arranging the aforementioned core in a mold having a cavity that accommodates the aforementioned core; and

[0011] The steps of forming the molded product using the aforementioned mold,

[0012] The aforementioned mold has multiple pins protruding into the aforementioned mold cavity.

[0013] In the step of configuring the aforementioned core, at least one of the aforementioned pins is not fixed, and each pin functions as a positioning pin.

[0014] In the step of molding the molded article, at least one of the aforementioned pins is fixed, and each pin functions as a core support pin that supports the aforementioned core relative to the resin pressure during molding.

[0015] According to the present invention, an apparatus and method for manufacturing a reactor can be provided, which can take into account both the dimensional deviation of the absorber core and the deformation caused by the resin pressure during molding.

[0016] 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

[0017] Figure 1 It is a schematic top view showing the outline of a mold for a manufacturing apparatus related to the relevant technology.

[0018] Figure 2 This is a schematic top view showing an outline of the mold of the manufacturing apparatus according to Embodiment 1.

[0019] Figure 3 This is a schematic side view showing the structure of the mold of the manufacturing apparatus according to Embodiment 1.

[0020] Figure 4 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 1 during positioning.

[0021] Figure 5 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 1, showing the upper mold descending.

[0022] Figure 6 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 1 during molding.

[0023] Figure 7 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 1, showing the removal of the molded article.

[0024] Figure 8 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 2 during positioning.

[0025] Figure 9 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 2, showing the upper mold descending.

[0026] Figure 10 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 2 during molding.

[0027] Figure 11This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 2, showing the process of removing the molded article.

[0028] Figure 12 This is a schematic side view showing the structure of the mold of the manufacturing apparatus according to Embodiment 3.

[0029] Figure 13 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 3 during positioning.

[0030] Figure 14 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 3, showing the upper mold descending.

[0031] Figure 15 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 3 during molding.

[0032] Figure 16 This is a schematic side view of the mold of the manufacturing apparatus according to Embodiment 3, showing the process of removing the molded article. Detailed Implementation

[0033] Discussion of implementation methods

[0034] First, the research conducted by the inventors of this invention will be explained. Figure 1 This is a schematic top view showing the outline of the mold 200 of the related manufacturing apparatus. The related manufacturing apparatus is a reactor manufacturing apparatus having a core 10. Resin is injected into the core 10 inserted into the mold 200 and around the molded coil 20, which is molded with resin, to perform insert molding. Reference numeral R1 indicates the resin included in the coil 20. Hole h is an insertion hole for bolts, etc., formed of resin. The resin flow path during molding includes inner flow paths 31a and 31b flowing inside the core 10, and outer flow path 32 flowing outside the core 10. Figure 1 This indicates the internal state of the mold 200 during the embedding and molding process.

[0035] 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 along the negative Z-axis.

[0036] The mold 200 has a cavity for receiving the core 10. For example, a pair of E-shaped cores 10 are inserted into the mold cavity. The core 10 has a base core 11, a middle core 12, and outer cores 13a and 13b. Hereinafter, without distinguishing between the outer cores 13a and 13b, they are sometimes simply referred to as outer core 13. The middle core 12 and the outer core 13 project from the base core 11 in the same direction. The width of the outer core 13 (e.g., its length in the X-axis direction) is shorter than the width of the middle core 12. Figure 1 In the diagram, the X-axis direction represents the extension direction of the base core 11, and the Y-axis direction represents the extension direction of the middle core 12 and the outer core 13.

[0037] The mold 200 has pins P11, P12, P13, P14, P21, P22, and P23 protruding into the mold cavity. Pins P21 and P22 contact the end face of the core 10 in the negative X-axis direction, and pins P11 and P12 contact the end face of the core 10 in the positive X-axis direction. Pin P23 contacts the end face of the core 10 in the negative Y-axis direction, and pins P13 and P14 contact the end face of the core 10 in the positive Y-axis direction. During molding, since no resin is injected into the parts in contact with pins P11, P12, P13, P14, P21, P22, and P23, windows corresponding to pins P11, P12, P13, P14, P21, P22, and P23 are formed in the molded article.

[0038] Pins P11 to P14 are connected to the mold 200 via spring S, but are not fixed. Pins P21 to P23 are fixed to the mold 200. Spring S can be a metal spring such as a coil spring or leaf spring, a fluid spring such as an air spring, or a spring made of elastic material such as rubber or resin. Hereinafter, when pins P11 to P14 are not distinguished from each other, they are sometimes simply referred to as pin P1. In addition, when pins P21 to P23 are not distinguished from each other, they are sometimes simply referred to as pin P2. It is also possible to consider that the position of pin P2 remains constant, and the position of pin P1 shifts in response to the pressure borne by the core 10. Moreover, when pins P1 and P2 are not distinguished from each other, they are sometimes simply referred to as pin P.

[0039] Furthermore, at least one of the pin P that contacts the end face of the core 10 in the positive X-axis direction and the pin P that contacts the end face of the core 10 in the negative X-axis direction can be connected to the spring S. Similarly, at least one of the pin P that contacts the end face of the core 10 in the positive Y-axis direction and the pin P that contacts the end face of the core 10 in the negative Y-axis direction can be connected to the spring S.

[0040] Pins P11 and P12 are displaced along the positive X-axis according to the length of core 10 in the X direction. Pins P13 and P14 are displaced along the positive Y-axis according to the length of core 10 in the Y-axis direction. Thus, pins P11, P12, P13, P14, P21, P22, and P23 can position core 10 while absorbing dimensional deviations. The outer foot 13b of core 10 is pressurized along the negative X-axis due to the displacement of pins P11 and P12.

[0041] As described above, the resin flow path during molding includes inner flow paths 31a and 31b passing through the interior of the core 10, and an outer flow path 32 passing through the exterior of the core 10. The inner flow path 31a passes through the periphery of the coil molding part 20. When resin is preferentially injected into the inner flow path 31b compared to the outer flow path 32, the outer core 13b is pressurized along the positive X-axis direction by the resin through the inner flow path 31b. To prevent the outer core 13 from deforming from the outside, resin is sometimes preferentially injected into the inner flow path 31. Generally, since the pressure applied based on pins P11 and P12 is less than the resin pressure, it is not possible to prevent the outer core 13b from deforming from the outside, resulting in the problem of core 10 cracking.

[0042] Therefore, to prevent the core 10 from breaking during molding, it is necessary, for example, to increase the spring coefficient of the spring S and apply strong pressure to the outer core 13b along the negative X-axis direction. However, if the pressure applied based on pins P11 and P12 is set too high, there is a concern that the core 10 may break during positioning. Based on the above discussion, the inventors of this invention conceived of a technical solution for the implementation method.

[0043] Implementation Method 1

[0044] The present invention will now be described through embodiments of the technical solutions, but the technical solutions covered by the claims are not limited to the embodiments described below. Furthermore, not all structures described in the embodiments are necessarily necessary means of solving the problem.

[0045] The manufacturing apparatus according to Embodiment 1 will now be described with reference to the accompanying drawings. Figure 2 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.

[0046] Figure 2 The above figure shows the state of mold 100 when core 10 is configured. Figure 2 The diagram below shows the state of mold 100 during the molding process. The down arrow between the upper and lower diagrams indicates the changes in the state of mold 100. Figure 2 In the diagram above, pin P1 is connected to spring S, but... Figure 2In the diagram below, pin P1 is not connected to spring S. Furthermore, as mentioned above, pin P1 represents pins P11 through P14. Figure 2 The diagram above shows a situation where pin P1 is not fixed when core 10 is configured, and pin P1 is displaced by the pressure exerted on the core. When core 10 is configured in the mold cavity, each pin P functions as a locating pin.

[0047] Figure 2 The diagram below shows the case where pin P1 is fixed to the mold 100 during molding. Pins P11-P14 and P21-P23 prevent the core 10 from deforming due to the applied pressure indicated by the arrows. Furthermore, the downward arrows indicate the case where resin pressure is applied from both inner flow paths 31. During molding, each pin P functions as a core support pin, supporting the core 10 relative to the resin pressure during molding.

[0048] The state where pin P1 is not fixed and the state where pin P1 is fixed switch depending on the opening and closing of mold 100. Since the core 10 is configured when mold 100 is open, therefore... Figure 2 In the diagram above, pin P1 is not fixed. Because mold 100 is closed during molding, therefore... Figure 2 In the diagram below, pin P1 is fixed. Furthermore, the specific structure of mold 100 will be described later.

[0049] Figure 3 This is a schematic side view showing the mold 100 included in the manufacturing apparatus according to Embodiment 1. In addition to the mold 100, the manufacturing apparatus according to Embodiment 1 may also include an opening and closing device (not shown) for controlling the opening and closing of the mold 100, a resin injection device (not shown), etc.

[0050] The mold 100 includes an upper mold 110 and a lower mold 120. The mold 100 is in a closed state when the upper mold 110 descends, and in an open state when the upper mold 110 rises. The upper mold 110 includes a wedge pressing pin 111 and a spring 112 extending along the Z-axis direction.

[0051] The wedge pressing pin 111 is connected to the upper mold 110 via a spring 112 that extends and retracts along the Z-axis. When the mold 100 is closed, the wedge pressing pin 111 presses down on the wedge 124 (described later), placing the wedge 124 between the pin P1 and the sliding core block 122 (described later), thereby fixing the pin P1. The spring 112 applies a force to the wedge pressing pin 111 to press down on the wedge 124. The load of the spring 112 is greater than the load of the spring 125 (described later).

[0052] The lower mold 120 includes a protrusion 121, a sliding core block 122, a spring 123, a wedge 124, a spring 125, a pin P1, and a spring S. The protrusion 121 has a protrusion along the Z-axis direction and can move along the Z-axis direction.

[0053] The sliding core block 122 is connected to the lower mold 120 via a spring 123 that extends and retracts along the X-axis, and can move forward and backward along the X-axis. The sliding core block 122 has a through hole into which the protrusion 121 can be inserted. If the protrusion 121 is inserted into the through hole, the sliding core block 122 moves in the positive X-axis direction. If the protrusion 121 retracts from the through hole, the sliding core block 122 moves in the negative X-axis direction due to the elastic force of the spring 123.

[0054] Wedge 124 is connected to sliding core block 122 via spring 125, which extends and retracts along the Z-axis. Wedge 124 is formed in a wedge shape, narrowing in width (e.g., length in the X-axis direction) as it moves toward the negative Z-axis direction. Wedge 124 is retracted to a position where it does not interfere with pin P1 when core 10 is positioned, by the action of spring 125 (described later). During forming, wedge 124 is inserted between pin P1 and sliding core block 122, thereby fixing pin P1.

[0055] After the molding process is completed, the spring 125 opens the mold 100. After the wedge presses the pin 111 and retracts, the spring force causes the wedge 124 to float up. As a result, the pin P1 returns to its unfixed state, that is, it returns to a state where it can be moved by pressure.

[0056] Pin P1 functions as a positioning pin when configuring core 10. During molding, pin P1 functions as a core support pin that supports core 10 relative to the resin pressure during molding. The base end of pin P1 is connected to sliding core block 122 via a spring S (also called a transverse spring) that extends and contracts along the X-axis.

[0057] Pin P1 extends from its base end along the negative X-axis direction and contacts the end face of the core 10 on the positive X-axis side. Additionally, pin P1 extends from its base end along the positive X-axis direction and has an inclined end face capable of engaging with the end face of the wedge 124 on the negative X-axis side. The length of the spring S can also be appropriately set so that pin P1 does not engage with the wedge 124 when the wedge 124 is not pressed down.

[0058] When the mold 100 is open, i.e., when the upper mold 110 rises, pin P1 is not fixed by wedge 124, so spring S can absorb dimensional deviations of core 10. On the other hand, when the mold is closed, i.e., when the upper mold 110 falls, wedge 124 is pressed by wedge pressing pin 111, and pin P1 is fixed by wedge 124. Therefore, the manufacturing apparatus according to Embodiment 1 can simultaneously absorb dimensional deviations of core 10 and prevent deformation caused by resin pressure during molding.

[0059] Next, refer to Figures 4-7 The manufacturing method described in Implementation Method 1 will be explained in detail. Figure 4This is a schematic side view showing the mold 100 during positioning. With the upper mold 110 raised, the core 10 is positioned on the lower mold 120. If the protrusion 121 is moved along the negative Z-axis, the sliding core block 122 moves along the negative X-axis as indicated by the arrow. Then, the core 10 is positioned by the pin P1.

[0060] Figure 5 This is a schematic side view of the mold 100 as the upper mold 110 descends. The upper mold 110 descends as indicated by the arrow. Corresponding to the descent of the upper mold 110, the wedge pressing pin 111 begins to press the wedge 124. The force with which the wedge pressing pin 111 presses the wedge 124 can be appropriately set to a force that does not damage the core 10. For example, the wedge pressing pin 111 can press the wedge 124 with a predetermined force.

[0061] Figure 6 This is a schematic side view of the mold 100 during molding. When the upper mold 110 has finished descending, a clamping force acts in the mold 100, and pin P1 is fixed by wedge 124 and wedge pressing pin 111. Then, the wedge 124 is placed between pin P1 and sliding core block 122. If resin is injected into the mold 100, core pressing pin P1 is pressed along the positive X-axis as indicated by the arrow. Wedge 124 converts the resin pressure into a vertical force, and wedge pressing pin 111 presses against wedge 124 in the vertical direction. For example, pin P1 can be fixed by making the spring constant of spring 112 sufficiently high.

[0062] Figure 7 This is a schematic side view of the mold 100 when the molded article is removed. After the resin molding is completed, the upper mold 110 is raised as indicated by the upper arrow. This causes the wedge pressing pin 111 to retract, and the wedge 124 is lifted by the spring 125. Then, the sliding core block 122 is moved along the positive X-axis by moving the protrusion 121 along the positive Z-axis, thus removing the molded article. Furthermore, reference numeral R2 indicates the resin used to mold the article.

[0063] The manufacturing apparatus according to Embodiment 1 performs positioning while absorbing dimensional deviations in the core. During this time, pin P1 can be displaced by spring S. Furthermore, the manufacturing apparatus according to Embodiment 1 fixes pin P1 by a wedge mechanism during the molding process. Therefore, pin P1, which bears resin pressure, remains stationary, suppressing core deformation and preventing core breakage.

[0064] Implementation Method 2

[0065] Next, refer to Figures 8-11The manufacturing apparatus according to Embodiment 2 will be explained below. The differences from Embodiment 1 will be the focus of the explanation. In Embodiment 2, the mold 100a of the manufacturing apparatus is replaced by a cylinder 113 that drives the wedge pressing pin 111 vertically instead of the spring 112 described above. The load on the cylinder 113 is greater than the load on the spring 125.

[0066] Figure 8 This is a schematic side view of the mold 100a during positioning. First, the core 10 is positioned in the lower mold 120. Then, the sliding core block 122 moves in the negative X-axis direction as indicated by the arrow, positioning the core 10 via pin P1.

[0067] Figure 9 This is a schematic side view of the mold 100a as the upper mold 110a descends. As indicated by the arrows, the upper mold 110a descends. When the descent of the upper mold 110a is complete, a clamping force is applied to the mold 100a. At this point, the wedge 124 has not yet been pressed down by the wedge pressing pin 111.

[0068] As is well known, during the mold closing process of mold 100a, each component of mold 100a deforms slightly at the micrometer level. Therefore, when the descent of upper mold 110a is complete, if wedge pressing pin 111 presses wedge 124, there is a concern that the core 10 may break due to the deformation of each component being pressed by pin P1. Therefore, the timing of the completion of the descent of mold 100a and the timing of pressing wedge 124 are staggered.

[0069] Figure 10 This is a schematic side view of the mold 100a during molding. After the upper mold 110a has descended, the cylinder 113 is activated, moving the wedge pressing pin 111 along the negative Z-axis. With the mold 100a closed and the wedge pressing pin 111 descending via the cylinder 113, the wedge 124 is pressed by the wedge pressing pin 111. Thus, the wedge 124 enters between the pin P1 and the wedge pressing pin 111, fixing the position of the pin P1. The cylinder 113 can also apply pressure to the wedge pressing pin 111 with a specified load, for example. Then, resin is injected into the mold 100a, and the wedge 124 converts the resin pressure into a vertical force. The core 10 is pressed via the pin P1 and the wedge 124 by the wedge pressing pin 111.

[0070] Figure 11 This is a schematic side view of the mold 100a when the molded article is removed. As indicated by the arrows, if the upper mold 110a is raised, the wedge pressing pin 111 retracts, and the wedge 124 is lifted by the spring 125. Alternatively, the upper mold 110a can be raised after the wedge pressing pin 111 is raised by the cylinder 113. After the sliding core block 122 is moved in the positive X-axis direction, the molded article is removed.

[0071] The manufacturing apparatus according to Embodiment 2 utilizes a cylinder to stagger the timing of the mold's descent and the timing of pin P1 being fixed by a wedge. This prevents core breakage due to deformation of components caused by the mold's closing force.

[0072] Alternatively, an electric or hydraulic drive mechanism can be provided instead of the cylinder 113 described above. However, the drive mechanism needs to be able to withstand the temperature of the mold 100a. Alternatively, the pin pressing component described later can be driven vertically instead of the wedge pressing pin 111.

[0073] Implementation Method 3

[0074] Next, refer to Figure 12 The manufacturing apparatus according to Embodiment 3 is described below. The mold 100b of the manufacturing apparatus according to Embodiment 3 includes an upper mold 110b and a lower mold 120b. (Comparison...) Figure 3 and Figure 12 The upper mold 110b does not have a wedge pressing pin 111 but has a pin pressing component 114. The pin pressing component 114 presses the pin P1a (described later) by closing the mold 100b. The pin pressing component 114 can also be fixed to the upper mold 110b.

[0075] Furthermore, the lower mold 120b does not have the wedge 124, and pin P1 is replaced by pin P1a. Pin P1a has a contact surface that contacts the lower surface of the pin pressing member 114. Pin P1a is fixed relative to the mold 100b by the friction between the pin pressing member 114 and pin P1a. The upper surface of pin P1a may also have a friction member, for example.

[0076] In the same way as in Embodiment 1, the spring S absorbs the dimensional deviation of the core 10, and the pin P1a, which bears the resin pressure, is fixed by friction to prevent deformation of the core 10.

[0077] Next, refer to Figures 13-16 This describes the manufacturing method involved in Implementation Method 3. Figure 13 This is a schematic side view showing the mold 100b in the positioning position. With the upper mold 110b raised, the core 10 is positioned in the lower mold 120b. The core 10 is positioned by the pin P1a through the sliding core block 122 moving along the negative X-axis.

[0078] Figure 14 This is a schematic side view of the mold 100b when the upper mold 110b is descending. As indicated by the arrows, the upper mold 110b descends. When the descent of the upper mold 110b is complete, a closing force is applied to the mold 100b. At this time, the upper surface of the pin P1a is pressed along the negative Z-axis by the pin pressing member 114, and the position of the pin P1a in the X-axis direction is fixed by friction.

[0079] Figure 15 This is a schematic side view showing the mold 100b during molding. Resin is injected into the mold 100b, and pin P1a bears resin pressure in the direction indicated by the arrow. Pin P1a is fixed by frictional force in the negative X-axis direction from the pin pressing member 114.

[0080] Figure 16 This is a schematic side view of the mold 100b when the molded article is removed. When resin molding is complete, as indicated by the upper arrow, the upper mold 110b rises, and the pin pressing member 114 retracts. Simultaneously with the retraction of the pin pressing member 114, the pin P1a returns to a state where it is supported by the spring S. After the sliding core 122 moves in the direction indicated by the right arrow, the molded article is removed.

[0081] The manufacturing apparatus according to Embodiment 3 absorbs and positions the core according to dimensional deviations. At this time, pin P1a is supported by spring S, allowing it to be displaced. On the other hand, during molding, pin P1a is fixed by friction, preventing the core from deforming and breaking.

[0082] The embodiments one through three can be appropriately combined. For example, in embodiment three, the pin pressing component 114 can also be driven by the cylinder 113.

[0083] 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.

[0084] 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 has multiple pins protruding into the mold cavity. When the core is positioned in the mold cavity, at least one of the plurality of pins is not fixed, and each pin functions as a positioning pin. During the molding process, at least one of the pins is fixed, and each pin functions as a core support pin that supports the core relative to the resin pressure during molding. The mold has a pin pressing component. When the mold is closed, at least one of the pins is pressed by the pin pressing component, and at least one of the pins is fixed by the frictional force between at least one of the pins and the pin pressing component.

2. The reactor manufacturing apparatus according to claim 1, characterized in that, The mold has a drive mechanism that drives the pin pressing component in the vertical direction. When the mold is closed and the pin pressing component is lowered by the drive mechanism, at least one of the pins is pressed by the pin pressing component.

3. The reactor manufacturing apparatus according to claim 1 or 2, characterized in that, When the core is positioned in the mold cavity, at least one of the pins is displaced in response to pressure exerted on the core.

4. The reactor manufacturing apparatus according to claim 1 or 2, characterized in that, The manufacturing apparatus is a reactor manufacturing apparatus having a pair of E-shaped cores. The width of the outer core of each E-shaped core is shorter than the width of the middle core of each E-shaped core.

5. A method for manufacturing a reactor having a core, comprising: The step of arranging the core in a mold having a cavity for receiving the core; as well as The step of forming the molded article using the mold, The mold has multiple pins protruding into the mold cavity. In the step of configuring the core, at least one of the plurality of pins is not fixed, and each pin functions as a positioning pin. In the molding process, at least one of the pins is fixed, and each pin functions as a core support pin that supports the core relative to the resin pressure during molding. The mold has a pin pressing component. When the mold is closed, at least one of the pins is pressed by the pin pressing component, and at least one of the pins is fixed by the frictional force between at least one of the pins and the pin pressing component.

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