reactor

Abstract

Provided is an electric reactor that can be easily manufactured and that can improve quality. The electric reactor includes a powder core portion composed of a press powder formed body of soft magnetic powder, a resin core portion composed of a formed body of a composite material in which soft magnetic powder is dispersed in resin, and an integrated formed member in which the powder core portion is formed with the resin core portion as an embedded member. The powder core portion has a low portion that is lower than a flat portion in other portions in a height along a compression direction when being formed, in an outer periphery observed along the compression direction. The resin core portion is connected to a portion of the powder core portion when observed along the compression direction and is formed to be flush with the flat portion. The low portion in the outer periphery of the powder core portion observed along the compression direction has a connected low portion that is connected to the resin core portion and an unconnected low portion that is not connected to the resin core portion, and the connected low portion is provided separately from the unconnected low portion.

Description

Technical Field

[0001] This disclosure relates to reactors. Background Technology

[0002] Conventionally, reactors have existed that include a coil, a core, and an insulating resin portion (see, for example, Patent Document 1). The core has a central core portion, two side core portions, and two end core portions. The central core portion is arranged to penetrate the inner side of the coil. The two side core portions extend parallel to the central core portion on the outer side of the coil and are arranged sideways to the central core portion. The two end core portions are arranged to connect the ends of the central core portion and the ends of the two side core portions. The insulating resin portion covers at least a portion of the coil and the core. Furthermore, the core includes an integrally molded member comprising a pressed powder core portion formed from a pressed powder molded body of soft magnetic powder and a resin core portion formed from a molded body of a composite material formed by dispersing soft magnetic powder in resin, with the pressed powder core portion being molded as an insert. According to this structure, the reactor can achieve a reduction in leakage flux and a reduction in losses.

[0003] [Existing Technical Documents]

[0004] [Patent Literature]

[0005] Patent Document 1: Japanese Patent Application Publication No. 2022-45166

[0006] [The problem the invention aims to solve]

[0007] However, the integrally molded components in reactors like those described above are difficult to manufacture. For example, the powder-pressed iron core portion of the integrally molded component can improve the durability of the mold during molding by configuring it to have a lower portion along the compression direction when viewed from the outer periphery, which is lower than other portions. However, if the lower portion is formed on the entire circumference of the outer periphery of the powder-pressed iron core portion, the mold used to mold the resin iron core portion as an insert requires a complex shape, and the molten composite material at the lower portion may leak into unwanted areas. Therefore, the quality of the integrally molded component, and thus the reactor, may be reduced. Summary of the Invention

[0008] The purpose of this disclosure is to provide a reactor that is easy to manufacture and can improve quality.

[0009] [Methods used to solve problems]

[0010] The reactor disclosed herein comprises: a coil; and an iron core having a central iron core portion, two side iron core portions, and two end iron core portions. The central iron core portion is arranged to penetrate the inner side of the coil. The two side iron core portions extend parallel to the central iron core portion on the outer side of the coil and are arranged laterally to the central iron core portion. The two end iron core portions are arranged to connect the ends of the central iron core portion to the ends of the two side iron core portions. The iron core includes a powder-pressed iron core portion and a resin iron core portion. The powder-pressed iron core portion is composed of a powder-pressed molded body of soft magnetic powder, and the resin iron core portion is composed of a molded body of a composite material formed by dispersing soft magnetic powder in resin. The iron core includes a powder-pressed iron core portion of soft magnetic powder dispersed in resin. An integrally molded component having the pulverized iron core portion as an insert is described. In the integrally molded component, the pulverized iron core portion has a low portion on its outer periphery as viewed along the compression direction during molding. The height of the low portion along the compression direction is lower than the flat portions of other parts. The resin iron core portion is connected to a part of the pulverized iron core portion and is formed to be flush with the flat portions when viewed along the compression direction. The low portion has a connecting low portion and a non-connecting low portion on its outer periphery as viewed along the compression direction. The connecting low portion is connected to the resin iron core portion, and the non-connecting low portion is not connected to the resin iron core portion. The connecting low portion and the non-connecting low portion are separately disposed.

[0011] [Invention Effects]

[0012] The reactor according to this disclosure can improve quality while being easy to manufacture. Attached Figure Description

[0013] Figure 1 This is a perspective view of a reactor according to one embodiment.

[0014] Figure 2 This is a perspective view of a portion of a reactor according to one embodiment.

[0015] Figure 3 This is a top view of a reactor according to one embodiment.

[0016] Figure 4 This is an exploded perspective view of a portion of a reactor according to one embodiment.

[0017] Figure 5 This is an exploded perspective view of a portion of a reactor according to one embodiment.

[0018] Figure 6 This is a top view of a portion of a reactor according to one embodiment.

[0019] Figure 7 This is a top view of an integrally formed component according to one embodiment.

[0020] Figure 8 This is a side view of an integrally formed component according to one embodiment.

[0021] Figure 9 This is a perspective view of an integrally molded component according to one embodiment.

[0022] Figure 10 This is an exploded perspective view of an integrally molded component according to one embodiment.

[0023] Figure 11 It is along Figure 3 A sectional view along line 11-11.

[0024] Figure 12 It is along Figure 3 A sectional view along line 12-12.

[0025] Figure 13 This is a perspective view of the second end covering portion according to one embodiment.

[0026] Figure 14 This is an enlarged perspective view of a portion of a reactor according to one embodiment.

[0027] Figure 15 This is an enlarged perspective view of a portion of a reactor according to one embodiment.

[0028] Figure 16 This is an enlarged side view of a portion of a reactor according to one embodiment.

[0029] Figure 17 It is along Figure 16 A sectional view along line 17-17.

[0030] Label Explanation

[0031] 20 reactors

[0032] 30 coils

[0033] 31 winding section

[0034] 32 end part

[0035] 33 terminal part

[0036] 40 iron core

[0037] 41 Intermediate core section

[0038] 41a First intermediate core structure section

[0039] 41b Second intermediate core structure section

[0040] 42 side core sections

[0041] 43-end iron core section

[0042] 44 Powder-pressed iron core section

[0043] 44a Flat section

[0044] 44b lower part

[0045] 44c connection bottom

[0046] 44d unconnected lower part

[0047] 45 Powder-pressed Iron Core Section

[0048] 45a Flat section

[0049] 45b lower part

[0050] 46 Resin Core

[0051] 46a lower bulge

[0052] 47 One-piece molded components

[0053] 48 Powder-pressed iron core components

[0054] 50 Insulating Resin Section

[0055] 60 First end covering portion

[0056] 61 End support section

[0057] 62 arm

[0058] 62a support surface

[0059] 63 Heat dissipation plate

[0060] 64 side panel

[0061] 64a Inclined section

[0062] 70 Second end covering portion

[0063] 71 End support

[0064] 71a End Through Hole

[0065] 71b flow channel

[0066] 71c inclined surface

[0067] 80 Molding Resin Section

[0068] 81 Gate Marks

[0069] 82 First Wall

[0070] 83 Second Wall

[0071] 83a concave part

[0072] 84 Wall Connection Part

[0073] 85 Fixed Part

[0074] 86 metal collar

[0075] 90 sliding core

[0076] 100 heat dissipation components

[0077] 101 heat sink base

[0078] 102 heatsink

[0079] 110 mold

[0080] 110a plane

[0081] L1 central axis

[0082] X-axis

[0083] X1 First Direction

[0084] X2 First opposite direction

[0085] Y-axis

[0086] Z-axis

[0087] Z1 upward direction

[0088] Z2 downward direction Detailed Implementation

[0089] [Description of embodiments of this disclosure]

[0090] First, embodiments of this disclosure will be described.

[0091] [1] The reactor of this disclosure comprises: a coil; and an iron core having a central iron core portion, two side iron core portions and two end iron core portions, the central iron core portion being disposed through the inner side of the coil, the two side iron core portions extending parallel to the central iron core portion on the outer side of the coil and arranged sideways to the central iron core portion, and the two end iron core portions being disposed such that the ends of the central iron core portion are connected to the ends of the two side iron core portions, wherein the iron core includes a pressed powder iron core portion and a resin iron core portion, the pressed powder iron core portion being composed of a pressed powder molded body of soft magnetic powder, and the resin iron core portion being composed of a molded body of a composite material formed by dispersing soft magnetic powder in resin, and the iron core comprising a pressed powder molded body of soft magnetic powder in resin. The pressed iron core portion is formed as an insert in an integrally molded component having the resin iron core portion. In the integrally molded component, the pressed iron core portion has a low portion on its outer periphery as viewed along the compression direction during molding. The height of the low portion along the compression direction is lower than the flat portion of other parts. The resin iron core portion is connected to a part of the pressed iron core portion and is formed to be flush with the flat portion when viewed along the compression direction. The low portion has a connecting low portion and a non-connecting low portion on its outer periphery as viewed along the compression direction. The connecting low portion is connected to the resin iron core portion, and the non-connecting low portion is not connected to the resin iron core portion. The connecting low portion and the non-connecting low portion are separately disposed.

[0092] According to this structure, the pulverized iron core has a low portion on its outer periphery as observed along the compression direction during forming. The height of this low portion along the compression direction is lower than the flat portions of other parts, thus improving, for example, the durability of the mold used to form the pulverized iron core. Furthermore, since the connecting low portion connected to the resin iron core and the non-connecting low portion not connected to the resin iron core are separately provided, the mold used to form the resin iron core can be made into a simple shape, and it is possible to prevent molten composite material from flowing into the non-connecting low portion. Therefore, it is possible to maintain a high quality of the integrally formed component and thus the reactor while facilitating manufacturing.

[0093] [2] In the above [1], it is also possible that, in the integrally formed component, the powder-pressed iron core portion constitutes part of the end iron core portion and is formed to both ends of the end iron core portion along the direction connecting the intermediate iron core portion and the two side iron core portions, and the flat portion that separates the connecting low portion and the non-connecting low portion is formed to both ends of the powder-pressed iron core portion along the direction connecting the intermediate iron core portion and the two side iron core portions.

[0094] According to this structure, a flat portion separating the connecting lower portion and the non-connecting lower portion is formed at both ends of the powder-pressed iron core portion along the direction connecting the middle iron core portion and the two side iron core portions, thus enabling the connecting lower portion and the non-connecting lower portion to be separated in a simple shape.

[0095] [3] In the above [1] or above [2], the iron core may be composed of the integral forming component and the powder-pressed iron core component. The integral forming component has a part of the middle iron core portion, the two side iron core portions and one of the two end iron core portions. The powder-pressed iron core component is composed of the powder-pressed iron core portion. The powder-pressed iron core portion has a part of the middle iron core portion and one of the two end iron core portions.

[0096] According to this structure, the iron core is composed of an integrally formed component and a powder-pressed iron core component, wherein the powder-pressed iron core component is composed of a powder-pressed iron core section. Therefore, it is sufficient that only one of the two components constituting the iron core is an integrally formed component. Thus, for example, compared to the case where both components constituting the iron core are integrally formed components, the manufacture of the iron core and thus the reactor becomes easier.

[0097] [Details of the embodiments disclosed herein]

[0098] Hereinafter, specific examples of the reactors of this disclosure will be described with reference to the accompanying drawings. In the drawings, for ease of explanation, parts of the structure are sometimes shown exaggeratedly or simplified. For example, in some figures, a portion of the chamfer shape is sometimes omitted. Furthermore, the dimensional ratios of the various parts sometimes differ in the drawings.

[0099] As used in this specification, "cylindrical" includes not only shapes with a continuous circumferential wall, but also shapes formed by combining multiple components to form a cylindrical shape. The outer circumferential shape of a "cylindrical" includes, but is not limited to, circles, ellipses, and polygons with sharp or rounded corners. "Cylindrical" is a shape having a through hole when viewed from above, including shapes where the outer circumferential shape is the same as the inner circumferential shape of the through hole, and shapes where the outer circumferential shape is different from the inner circumferential shape of the through hole. "Cylindrical" includes shapes extending axially along a central axis passing through the center of the through hole and having a defined length, the length of which is not limited.

[0100] The terms "first," "second," and "third" used in this manual are only used to distinguish objects and do not rank them.

[0101] Furthermore, the invention is not limited to these examples, but is shown in the claims and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0102] The figures illustrate a first axis X, a second axis Y orthogonal to the first axis X, and a third axis Z orthogonal to both the first axis X and the second axis Y. Additionally, the figures illustrate a first direction X1 along the first axis X and a first opposite direction X2. Furthermore, the figures illustrate an upward direction Z1 along the third axis Z and a downward direction Z2 opposite to the upward direction Z1. The upward direction Z1 and the downward direction Z2 represent, for example, the directions of the reactor 20 when it is fixed to a fixed object (not shown).

[0103] (Structure of reactor 20)

[0104] like Figures 1 to 3 As shown, the reactor 20 includes a coil 30, an iron core 40, and an insulating resin section 50. The reactor 20 is used, for example, as a component of a converter installed in vehicles such as electric vehicles and hybrid vehicles, or as a component of a power conversion device having such a converter. Examples of converters include DC-DC converters and AC-DC converters.

[0105] (Structure of coil 30)

[0106] like Figure 4 and Figure 5 As shown, the coil 30 has a winding portion 31 formed by winding the coil into a spiral shape. Known windings can be used as the winding. The winding in this embodiment is a coated flat wire having a conductor wire and an insulating coating. The conductor wire is, for example, a flat wire made of copper or a copper alloy. The insulating coating is, for example, made of enamel. The winding portion 31 is formed, for example, by flattening and winding the coated flat wire. The winding portion 31 is formed in a cylindrical shape. In this embodiment, the winding portion 31 is formed in a square cylindrical shape.

[0107] The coil 30 has end portions 32 and 33. The end portions 32 and 33 are integrally formed with the winding portion 31. That is, the end portions 32 and 33 are formed from the two ends of the winding portion 31. The insulation covering at the front end of each end portion 32 and 33 is peeled off to expose the conductor wire. The end portions 32 and 33 are respectively formed to extend outward from the winding portion 31. One end portion 32 extends outward along the outer side of the first axis X and along the outer side of the central axis of the winding portion 31. The other end portion 33 extends outward along the outer side of the second axis Y and along the outer periphery of the winding portion 31. The end portions 32 and 33 are respectively connected to a connection terminal (not shown) in the device carrying the reactor 20 by means of, for example, welding.

[0108] (Structure of core 40)

[0109] like Figure 6As shown, the core 40 has a central core portion 41, two side core portions 42, and two end core portions 43. The central core portion 41 is arranged to pass through the inner side of the coil 30, specifically the inner side of the winding portion 31. The two side core portions 42 extend parallel to the central core portion 41 on the outer side of the coil 30 and are arranged on the sides of the central core portion 41, sandwiching it. The two end core portions 43 are arranged to connect the ends of the central core portion 41 and the ends of the two side core portions 42.

[0110] In addition, such as Figure 4 and Figure 6 As shown, corresponding to the classification of manufacturing methods, the iron core 40 includes powder-pressed iron core portions 44 and 45 and a resin iron core portion 46, and includes an integrally molded member 47 in which the powder-pressed iron core portion 44 is formed as an insert and the resin iron core portion 46 is formed therein. The powder-pressed iron core portions 44 and 45 are composed of powder-pressed molded bodies of soft magnetic powder. The resin iron core portion 46 is composed of a molded body of a composite material formed by dispersing soft magnetic powder in resin.

[0111] Materials that can be used as soft magnetic powders include, for example, pure iron, iron alloys, and ferritic nonmetals. Examples of iron alloys include Fe-Si alloys and Fe-Ni alloys.

[0112] Resins used in composite materials include, for example, thermosetting resins and thermoplastic resins. Examples of thermosetting resins include epoxy resins, phenolic resins, silicone resins, and polyurethane resins. Examples of thermoplastic resins include polyphenylene sulfide (PPS) resins, polyamide (PA) resins (e.g., nylon 6, nylon 66, nylon 9T, etc.), liquid crystal polymers (LCPs), polyimide (PI) resins, and fluoropolymers. In addition to resins, composite materials may also contain fillers.

[0113] The core 40 in this embodiment is composed of an integrally formed member 47 and a powder-pressed core member 48. The integrally formed member 47 has a first intermediate core component 41a, which is part of an intermediate core portion 41, two side core portions 42, and one of two end core portions 43, which is an end core portion 43. The powder-pressed core member 48 is composed of a powder-pressed core portion 45, and has a second intermediate core component 41b, which is part of an intermediate core portion 41, and one of the two end core portions 43, which is an end core portion 43.

[0114] like Figure 10 As shown, in the integrally formed component 47, the powder-pressed iron core portion 44 constitutes the end iron core portion 43 (see reference). Figure 4 It is part of the first intermediate core component 41a (see reference). Figure 4It is formed into a T-shape as part of the integrally formed member 47. Furthermore, in the integrally formed member 47, the pressed iron core portion 44 has a low portion 44b on its outer periphery as viewed along the compression direction during forming. The height of this low portion 44b along the compression direction is lower than that of the flat portions 44a in other portions. Moreover, the low portion 44b is, for example, a step designed to improve the durability of the mold when forming the pressed iron core portion 44. In this embodiment, the flat portion 44a and the low portion 44b are connected by a curved surface that changes with a very smooth height. Additionally, in... Figure 10 The resin core 46, which is integrally formed with the powder-pressed iron core 44 and not separately formed, is schematically illustrated in a state separate from the powder-pressed iron core 44. The compression direction is along the third axis Z in the figure. In this embodiment, the upper surface (Z1) of the integrally formed member 47 is described, but the lower surface (Z2) of the integrally formed member 47 is also provided with the same shape.

[0115] In addition, such as Figure 4 and Figure 8 As shown, in the integrally molded member 47, the resin core portion 46 is connected to a portion of the powder-pressed core portion 44 when viewed along the compression direction, and is formed flush with the flat portion 44a. Furthermore, in the integrally molded member 47, the resin core portion 46 is also formed flush with the side surface of the powder-pressed core portion 44.

[0116] And, as Figure 8 and Figure 10 As shown, the lower portion 44b has a connecting lower portion 44c connected to the resin core portion 46 and a non-connecting lower portion 44d not connected to the resin core portion 46 on the outer periphery of the powder core portion 44 as viewed along the compression direction. These connecting lower portions 44c and non-connecting lower portions 44d are provided separately. In other words, the connecting lower portions 44c and non-connecting lower portions 44d are not connected by a flat portion 44a provided between them.

[0117] like Figure 6 As shown, in this embodiment, in the integrally formed member 47, the powder-pressed iron core portion 44 constitutes a part of the end iron core portion 43, and is formed at both ends of the end iron core portion 43 along the direction connecting the intermediate iron core portion 41 and the two side iron core portions 42. Furthermore, the connecting lower portion 44c (refer to...) Figure 10 The flat portion 44a, separated from the non-connected lower portion 44d, is formed at both ends of the powder-pressed iron core portion 44 along the direction connecting the intermediate iron core portion 41 (more specifically, the first intermediate iron core component portion 41a) and the two side iron core portions 42. In other words, in the integrally formed member 47, the powder-pressed iron core portion 44 is formed at both ends of the end iron core portion 43 along the second axis Y, and the flat portion 44a is also formed at both ends of the end iron core portion 43 along the second axis Y.

[0118] In addition, such as Figure 4 As shown, in the integrally molded member 47 of this embodiment, the resin core portion 46 is formed in a shape that constitutes two side core portions 42, is part of the end core portion 43, and is part of the first intermediate core component portion 41a. The resin core portion 46 and the powder-pressed core portion 44 are formed together in an E-shape. Furthermore, as... Figure 8 and Figure 9 As shown, the resin core portion 46 of this embodiment has a downward bulge portion 46a that bulges downward in a direction Z2 from the portion corresponding to the first intermediate core component portion 41a.

[0119] like Figure 4 As shown, the powder-pressed iron core portion 45 constituting the powder-pressed iron core component 48 is formed in a T-shape to form the end iron core portion 43 and the second intermediate iron core component portion 41b. The powder-pressed iron core portion 45 constituting the powder-pressed iron core component 48 has a low portion 45b on its outer periphery as viewed along the compression direction during forming. The height of this low portion 45b along the compression direction is lower than that of the flat portion 45a in other portions. Furthermore, the low portion 45b is, for example, a step designed to improve the durability of the mold when forming the powder-pressed iron core portion 45. In this embodiment, the flat portion 45a and the low portion 45b are connected by a curved surface with a smoothly varying height. The compression direction is along the third axis Z in the figure. In this embodiment, the upper surface (Z1) of the powder-pressed iron core component 48 is described, but the lower surface (Z2) of the powder-pressed iron core component 48 also has the same shape. The lower part 45b of the powder-pressed iron core portion 45 constituting the powder-pressed iron core component 48 is formed on the entire circumference of the outer periphery of the powder-pressed iron core portion 45 as viewed along the compression direction.

[0120] (Structure of insulating resin part 50)

[0121] like Figures 1 to 3 As shown, the insulating resin portion 50 covers at least a portion of the coil 30 and the iron core 40. (As indicated...) Figure 2 As shown, the insulating resin part 50 has a first end covering part 60 and a second end covering part 70 that are formed as a primary molding part and constitute two end covering parts, and a molding resin part 80 that is formed as a secondary molding part.

[0122] The materials used for the first end covering portion 60, the second end covering portion 70, and the molding resin portion 80 can be, for example, thermoplastic resins. Examples of thermoplastic resins include polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP) resin, and polyamide (PA) resin. Examples of thermoplastic resins include polybutylene terephthalate (PBT) resin and acrylonitrile-butadiene-styrene (ABS) resin. The materials used for the first end covering portion 60, the second end covering portion 70, and the molding resin portion 80 can be the same or different.

[0123] (Structure of the first end covering portion 60 and the second end covering portion 70)

[0124] like Figure 4 and Figure 5 As shown, the first end covering portion 60 and the second end covering portion 70 are capable of covering the unassembled iron core 40 (see reference). Figure 4 The coil 30 is configured with its two ends in a manner that resembles a coil 30 in its assembled state with the iron core 40. Furthermore, the first end covering 60 and the second end covering 70 are configured in the same manner as the coil 30 and the iron core 40 in their assembled state (see reference). Figure 2 and Figure 6 The winding portion 31 is positioned between the coil 30 and the end core portion 43. Specifically, the first end cover portion 60 is formed to cover the end of the winding portion 31 in the first direction X1 and can be mounted to that end. In addition, the second end cover portion 70 is formed to cover the end of the winding portion 31 in the first opposite direction X2 and can be mounted to that end.

[0125] Furthermore, the first end cover portion 60 has an end support portion 61 that supports the end portion 32 extending along the first axis X. The end support portion 61 supports the base of the end portion 32 where the insulation covering has not been peeled off. Additionally, the second end cover portion 70 has an end support portion 71 that supports the end portion 33 extending along the second axis Y. The end support portion 71 supports the base of the end portion 33 where the insulation covering has not been peeled off.

[0126] In addition, such as Figure 5 As shown, the first end cover 60 has two arms 62 that extend in connection with the second end cover 70 and are capable of supporting the lower part of the coil 30. The two arms 62 extend from both ends along the second axis Y along the first axis X at their lower Z2 ends of the first end cover 60.

[0127] like Figure 12 As shown, the two arms 62 have curved support surfaces 62a, which can support the curved surfaces at both ends of the winding portion 31 of the coil 30 along the second axis Y from the lower direction Z2 toward the upper direction Z1.

[0128] In addition, such as Figure 5 As shown, the first end cover portion 60 has a heat dissipation plate portion 63. (As indicated...) Figure 11 and Figure 12 As shown, the heat dissipation plate 63 is disposed between the lower surface of the intermediate iron core 41 and the coil 30. Figure 11 As shown, the heat dissipation plate portion 63 of this embodiment is shaped to cover the entire lower surface of the first intermediate core component portion 41a within the intermediate core portion 41, and more specifically, it is shaped to cover the entire lower bulge portion 46a. That is, the heat dissipation plate portion 63 of this embodiment is disposed between the lower surface of the first intermediate core component portion 41a and the coil 30, where the distance is narrowed due to the presence of the lower bulge portion 46a.

[0129] In addition, such as Figure 5 As shown, the first end covering portion 60 has a side plate portion 64. (As indicated...) Figure 12 As shown, the side plate portion 64 is erected from both sides of the heat dissipation plate portion 63 and is positioned between the side of the central iron core portion 41 and the coil 30. Figure 5 As shown, the side plate portion 64 has an inclined portion 64a, which is closer to the front end in the direction of insertion into the coil 30 and is lower than the height of the heat dissipation plate portion 63.

[0130] (Structure of the molding resin section 80)

[0131] like Figure 2 and Figure 11 As shown, the molded resin portion 80 is formed in such a way that it covers at least a portion of the coil 30, the iron core 40, the first end covering portion 60, and the second end covering portion 70 in a state where they are assembled. In this embodiment, the molded resin portion 80 is formed to cover the coil 30, the iron core 40, the first end covering portion 60, and the second end covering portion 70, such that the upper surface, the lower surface, and the end portions 32 and 33 of the winding portion 31 in the coil 30 are exposed, while most of the others are not exposed.

[0132] like Figure 1 , Figure 3 and Figure 11 As shown, the molding resin section 80 has a gate mark 81. Furthermore, the gate mark 81 is a mark generated during the injection molding of the molding resin section 80, and is a mark generated corresponding to the molten resin passing through the gate.

[0133] like Figure 11As shown, the gate mark 81 is positioned such that the path between the upper surface of the intermediate core portion 41 above the heat dissipation plate portion 63 and the coil 30 is shorter than the path to the heat dissipation plate portion 63. In other words, the position of the gate mark 81 is set such that, during the molding of the molding resin portion 80, the molten resin forming the molding resin portion 80 reaches the upper surface of the intermediate core portion 41 above the heat dissipation plate portion 63 and the coil 30 before the heat dissipation plate portion 63.

[0134] Specifically, such as Figure 3 As shown, gate marks 81 are disposed on the upper surface of the molding resin portion 80. Viewed from above in the Z1 direction, gate marks 81 are disposed on the central axis L1 of the intermediate iron core portion 41. Viewed from above in the Z1 direction, two gate marks 81 are disposed on the central axis L1 of the intermediate iron core portion 41, at a position sandwiching the coil 30 and at a position further outward than the two ends of the coil 30. Furthermore, the gate marks 81 of the molding resin portion 80 are not limited to the two gate marks 81 described above; for example, they may be provided at a position further away from the heat dissipation plate portion 63 than the aforementioned gate marks 81.

[0135] In addition, such as Figures 15 to 17 As shown, the molding resin portion 80 has a first wall 82 that covers the surface of the end support portion 71 of the second end covering portion 70 that is close to the gate mark 81, and a second wall 83 that covers the surface of the end support portion 71 that is opposite to the gate mark 81. Furthermore, the gate mark 81 mentioned here is the gate mark 81 that is closest to the first wall 82 and the second wall 83.

[0136] In detail, firstly, as Figure 5 and Figure 14 As shown, the end support portion 71 in the second end covering portion 70 is provided at the end of the second end covering portion 70 in the upward direction Z1, on the end of the side from which the end portion 33 is extended. Figure 5 , Figure 13 and Figure 14 As shown, the end support portion 71 has an end through hole 71a that extends along the second axis Y so that the end portion 33 extending along the second axis Y can pass through.

[0137] And, as Figures 15 to 17 As shown, the first wall 82 is formed to cover the surface of the end support portion 71 that is near the gate mark 81 and the surface of the end support portion 71 in the first opposite direction X2. The second wall 83 is formed to cover the surface of the end support portion 71 that is opposite to the gate mark 81 and the surface of the end support portion 71 in the first direction X1.

[0138] Furthermore, the upper end face of the end support portion 71, the upper end face of the first wall 82, and the upper end face of the second wall 83 are formed to be flush. In addition, the end faces of the end portion 33 in the end support portion 71, the end faces of the end portion 33 in the first wall 82, and the end faces of the end portion 33 in the second wall 83 are formed to be flush.

[0139] In addition, such as Figure 15 As shown, the upper corner of the side where the end portion 33 is extended in the end support portion 71 has a flow channel 71b that connects the first wall 82 to the second wall 83. Furthermore, the molding resin portion 80 has a wall connection portion 84, which is disposed in the flow channel 71b and connects the first wall 82 and the second wall 83.

[0140] In addition, such as Figures 15 to 17 As shown, the second wall 83 has a recess 83a, which includes the side of the end support 71 opposite to the gate mark 81 and the side of the end support 71 in the first direction X1. Figure 17 As shown, the recess 83a is formed during the molding of the resin portion 80 by configuring a sliding core 90 that is different from the upper and lower molds. Additionally, as... Figure 14 and Figure 17 As shown, the side of the end support portion 71 opposite to the gate mark 81 and the surface of the end support portion 71 in the first direction X1 have an inclined surface 71c, which is used to allow the sliding core 90 (refer to...) Figure 17 It is easy to configure.

[0141] In addition, such as Figure 16 As shown, the recess 83a is positioned above the end portion 33. In other words, the recess 83a is positioned Z1 above the center of the end portion 33 along the third axis Z.

[0142] In addition, such as Figure 3 As shown, the molding resin portion 80 has a fixing portion 85. The molding resin portion 80 of this embodiment has three fixing portions 85. The three fixing portions 85 are provided in the molding resin portion 80 protruding outwards from the portion of the cover end iron core portion 43 and along the direction of the first axis X.

[0143] Specifically, one of the three fixing parts 85 protrudes in the molding resin part 80 along the central axis L1 of the intermediate iron core part 41 in a first direction X1. Additionally, two of the three fixing parts 85 protrude in the molding resin part 80 from both ends along the second axis Y in a first opposite direction X2. Metal collars 86 are fixed to each fixing part 85. The fixing parts 85 are fixed to the fixing object, for example, by bolts that pass through the metal collars 86 and engage with the fixing object.

[0144] like Figure 11 As shown, the reactor 20 configured as described above is disposed on the heat dissipation member 100 such that the lower surface of the exposed coil 30, specifically the lower surface of the winding portion 31, contacts the heat dissipation member 100. The heat dissipation member 100 is, for example, composed of a heat dissipation base 101 through which cooling water (not shown) flows and heat dissipation fins 102 disposed on the heat dissipation base 101 and in contact with the lower surface of the coil 30.

[0145] (Manufacturing method of reactor 20)

[0146] Next, the manufacturing method of the reactor 20 configured as described above and its function will be explained.

[0147] The manufacturing method of reactor 20 includes core manufacturing process, primary forming process, assembly process and secondary forming process.

[0148] In the core manufacturing process, an integrally formed component 47 and a powder-pressed core component 48 constituting the core 40 are formed. Here, the integrally formed component 47 is formed by first forming a powder-pressed core portion 44 and then forming a resin core portion 46 using this powder-pressed core portion 44 as an insert, thereby achieving overall forming. It should be noted that, as... Figure 7 and Figure 8 As shown, the connection between the resin core part 46 and the powder pressing core part 44 is flush with the powder pressing core part 44. Therefore, in the mold 110 used at this time, the part corresponding to the junction of the powder pressing core part 44 and the resin core part 46 is a simple plane 110a.

[0149] In a single molding process, a first end-covering portion 60 and a second end-covering portion 70, which constitute part of the insulating resin portion 50 and have two end-covering portions, are formed. In the single molding process of this embodiment, a heat dissipation plate portion 63 (see reference 63) disposed between the lower surface of the intermediate core portion 41 and the coil 30 is formed in the first end-covering portion 60. Figure 5 In addition, in the one-time forming process of this embodiment, the end support portions 61 and 71 of the end portions 32 and 33 of the support coil 30 are formed in the first end covering portion 60 and the second end covering portion 70.

[0150] Following the core manufacturing process and the initial forming process, the pre-manufactured coil 30, core 40, first end covering 60, and second end covering 70 are assembled in the assembly process. At this time, firstly as follows... Figures 5 to 4 As shown, the first end covering portion 60 and the second end covering portion 70 are assembled on the coil 30, and then further as follows: Figures 4 to 6 As shown, assemble the iron core 40.

[0151] Next, in the secondary molding process, a molding resin portion 80, which constitutes part of the insulating resin portion 50, is formed. In the secondary molding process of this embodiment, the molding resin portion 80 is formed with the heat dissipation plate portion 63 disposed between the lower surface of the intermediate iron core portion 41 and the coil 30.

[0152] Furthermore, in the secondary molding process of this embodiment, molten resin is injected from the portion that forms the gate mark 81, such that the molten resin that forms the molding resin portion 80 reaches the area between the upper surface of the intermediate iron core portion 41 and the coil 30 above the heat dissipation plate portion 63 before the heat dissipation plate portion 63. In other words, in the secondary molding process of this embodiment, molten resin is injected from the portion that forms the gate mark 81, such that the molten resin that forms the molding resin portion 80 presses the intermediate iron core portion 41 downward in the Z2 direction.

[0153] Furthermore, in the secondary molding process of this embodiment, a gate mark 81, a first wall 82 covering the surface of the end support 71 near the gate mark 81, and a second wall 83 covering the surface of the end support 71 opposite to the gate mark 81 are formed in the molding resin section 80. At this time, the sliding core 90 is brought into contact with the surface of the end support 71 opposite to the gate mark 81 and molten resin is injected, thereby forming a recess 83a in the second wall 83. In other words, in the secondary molding process, the sliding core 90 supports the surface of the end support 71 opposite to the gate mark 81, thereby preventing the end support 71 from shifting position, and forming a second wall 83 with a recess 83a. Thus, the manufacturing of the reactor 20 is completed.

[0154] (Effects of this implementation method)

[0155] Next, the effects of the above-described embodiments will be described.

[0156] (1) The pressed iron core portion 44 has a low portion 44b on its outer periphery as viewed along the compression direction during molding. The height of the low portion 44b along the compression direction is lower than that of the flat portion 44a in other portions, thus improving the durability of the mold when molding the pressed iron core portion 44. Furthermore, in the low portion 44b, the connecting low portion 44c connected to the resin iron core portion 46 and the non-connecting low portion 44d not connected to the resin iron core portion 46 are separately provided. Therefore, the mold 110 (refer to) when molding the resin iron core portion 46 can be used to mold the resin iron core portion 46. Figure 7 and Figure 8 It is formed into a simple shape and can prevent the molten composite material that forms the resin core 46 from flowing into the non-connected lower part 44d. Therefore, it is possible to maintain a high quality of the integrally formed component 47 and thus the reactor 20 while making it easy to manufacture.

[0157] (2) The powder-pressed iron core portion 44 in the integrally formed member 47 constitutes part of the end iron core portion 43 and is formed to both ends of the end iron core portion 43 along the direction connecting the intermediate iron core portion 41 and the two side iron core portions 42, i.e., along the second axis Y. Moreover, the flat portion 44a that separates the connecting lower portion 44c from the non-connecting lower portion 44d is formed to both ends of the powder-pressed iron core portion 44 along the direction connecting the intermediate iron core portion 41 and the two side iron core portions 42. Therefore, for example, the connecting lower portion 44c and the non-connecting lower portion 44d can be separated with a simple shape.

[0158] (3) The iron core 40 is composed of an integrally formed component 47 and a powder-pressed iron core component 48, wherein the powder-pressed iron core component 48 is composed of a powder-pressed iron core portion 45. Therefore, it is sufficient that only one of the two components constituting the iron core 40 is an integrally formed component 47. Thus, for example, compared to the case where both components constituting the iron core 40 are integrally formed components, the manufacture of the iron core 40 and thus the reactor 20 becomes easier.

[0159] (Modified example)

[0160] The above-described embodiments can be modified as follows. The above-described embodiments and the following modifications can be combined with each other to implement them within the scope of technical inconsistency.

[0161] In the above embodiment, the powder-pressed iron core portion 44 in the integrally formed member 47 is formed at both ends of the end iron core portion 43 along the second axis Y, but it is not limited to this, and it may also be a shape that does not form at both ends of the end iron core portion 43.

[0162] In the above embodiment, the iron core 40 is composed of an integrally formed component 47 and a powder-pressed iron core component 48, wherein the powder-pressed iron core component 48 is composed of a powder-pressed iron core portion 45, but is not limited thereto. For example, both components constituting the iron core 40 may be integrally formed components in which a resin iron core portion is formed as an insert. In addition, for example, the iron core 40 may be composed of three or more components.

[0163] The manufacturing method of the reactor 20 in the above embodiment can also be modified within the scope of being able to manufacture the same reactor 20.

[0164] In the above embodiment, the coil 30 is formed by flatly winding the wrapped flat wire into a square tube shape. However, as long as the structure has the same function, it can be changed to other shapes and structures.

[0165] In the above embodiment, the insulating resin portion 50 has a first end covering portion 60, a second end covering portion 70, and a molding resin portion 80, but it is not limited to this. For example, it may be configured to not have the first end covering portion 60 and the second end covering portion 70.

[0166] The embodiments disclosed herein are illustrative in all respects, and the invention is not limited to these illustrative examples. That is, the scope of the invention is set forth in the claims and is intended to include all modifications within the meaning and scope equivalent to the claims.

Claims

1. A reactor comprising: a coil; and a core having a central core portion, two side core portions, and two end core portions, the central core portion being disposed through the inner side of the coil, the two side core portions extending parallel to the central core portion and arranged laterally to the outer side of the coil, and the two end core portions being disposed such that an end portion of the central core portion is connected to an end portion of the two side core portions, wherein... The iron core includes a powder-pressed iron core portion and a resin iron core portion. The powder-pressed iron core portion is composed of a powder-pressed molded body of soft magnetic powder, and the resin iron core portion is composed of a molded body of a composite material formed by dispersing soft magnetic powder in resin. The iron core also includes an integrally molded component in which the powder-pressed iron core portion is formed as an insert, thus incorporating the resin iron core portion. In the integrally formed component, The pressed iron core portion has a low portion on its outer periphery as viewed along the compression direction during forming. The height of this low portion along the compression direction is lower than the flat portions of other parts. When viewed along the compression direction, the resin core portion is connected to a portion of the powder-pressed core portion and is formed flush with the flat portion. The lower portion has a connected lower portion and a non-connected lower portion on the outer periphery of the powder-pressed iron core portion as observed along the compression direction. The connected lower portion is connected to the resin iron core portion, and the non-connected lower portion is not connected to the resin iron core portion. The connecting lower part and the non-connecting lower part are separated.

2. The reactor according to claim 1, wherein, In the integrally formed component, the powder-pressed iron core portion constitutes part of the end iron core portion and is formed at both ends of the end iron core portion along the direction connecting the intermediate iron core portion and the two side iron core portions. The flat portion, which separates the connecting lower portion and the non-connecting lower portion, is formed at both ends of the powder-pressed iron core portion along the direction that connects the intermediate iron core portion and the two side iron core portions.

3. The reactor according to claim 1, wherein, The iron core is composed of the integrally formed component and the powder-pressed iron core component. The integrally formed component has a portion of the intermediate iron core portion, two side iron core portions, and one of the two end iron core portions. The powder-pressed iron core component is composed of the powder-pressed iron core portion, which has a portion of the intermediate iron core portion and one of the two end iron core portions.

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