Reactor manufacturing device and manufacturing method

Abstract

To provide an apparatus and a method for manufacturing a reactor which can prevent cracking of a core by a resin pressure in molding.SOLUTION: An apparatus for manufacturing a reactor having a core 10 includes a mold 100 having a cavity storing the core 10. The mold 100 includes a core support pin 110 which is brought into contact with the core 10 and supports the core 10 against a resin pressure in molding. A resin flow channel in molding includes an inside flow channel 31 passing through inside the core 10, and an outside flow channel 32 passing through outside the core 10. At a position where the width of the inside flow channel 31 is wider than the width of the outside flow channel 32, the core support pin 110 is arranged.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present disclosure relates to a reactor manufacturing apparatus and manufacturing method. [Background technology]

[0002] Patent Document 1 discloses a method for manufacturing a reactor including a primary molding step and a secondary molding step. According to the technique described in Patent Document 1, a common mold can be used for both the primary molding and the secondary molding. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2013-149841 A Summary of the Invention [Problem to be solved by the invention]

[0004] If the resin preferentially enters the outer periphery of the core in the secondary molding process, the core cannot be supported against the resin pressure, and high stress is generated in the core, which may cause the core to crack.

[0005] The present disclosure has been made to solve such problems, and has an object to provide a reactor manufacturing apparatus and manufacturing method that can prevent the core from cracking due to resin pressure during molding. [Means for solving the problem]

[0006] The reactor manufacturing apparatus in this embodiment includes: An apparatus for manufacturing a reactor having a core, comprising: A mold having a cavity for accommodating the core, the die includes a core support pin that contacts the core and supports the core against resin pressure during molding; a resin flow path during molding includes an inner flow path passing through the inside of the core and an outer flow path passing through the outside of the core; The core support pin is disposed at a position where the width of the inner flow passage is wider than the width of the outer flow passage.

[0007] The method for manufacturing a reactor in this embodiment includes the steps of: A method for manufacturing a reactor including a core, comprising the steps of: forming a molded article using a mold having a cavity for receiving the core; the die includes a core support pin that contacts the core and supports the core against resin pressure during molding; The resin flow path in the molding step includes an inner flow path passing through the inside of the core and an outer flow path passing through the outside of the core, The core support pin is disposed at a position where the width of the inner flow passage is wider than the width of the outer flow passage. Effect of the Invention

[0008] The present disclosure provides a reactor manufacturing apparatus and method capable of preventing the core from cracking due to resin pressure during molding. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic top view illustrating an overview of a mold according to a related art. [Diagram 2] FIG. 2 is a schematic top view showing the configuration of a core. [Diagram 3] FIG. 13 is a diagram showing the dimensional relationship between an inner flow passage and an outer flow passage of a mold according to the related art. [Figure 4] 1A to 1C are diagrams showing three modes in which a core may crack in a manufacturing apparatus according to the related art. [Diagram 5] FIG. 2 is a schematic top view showing a mold of the manufacturing apparatus according to the first embodiment. [Figure 6] FIG. 2 is a diagram showing the dimensional relationship between an inner flow path and an outer flow path of the mold according to the first embodiment. [Figure 7]FIG. 2 is a diagram showing a preferable dimensional relationship between flow paths of the mold according to the first embodiment. [Figure 8] FIG. 2 is a diagram showing a preferable dimensional relationship between flow paths of the mold according to the first embodiment. [Figure 9] FIG. 2 is a diagram showing a preferable dimensional relationship between flow paths of the mold according to the first embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Consideration leading to the embodiment First, the contents of the study carried out by the inventor of the present application will be described. FIG. 1 is a schematic top view showing an outline of a mold 200 of a related manufacturing device. The related manufacturing device is a manufacturing device for a reactor having a core. The related manufacturing device may further include an opening / closing device (not shown) for the mold 200 and a resin injection device (not shown). The core 10 and the coil mold 20 in which resin is molded are inserted into the mold 200. Reference character R1 represents the resin contained in the coil mold 20. Then, the resin is injected around the core 10 and the coil mold 20 to perform insert molding. In the molding process, a hole h, which is an insertion hole for a bolt or the like, is also formed. FIG. 1 shows the state inside the mold 200 during insert molding.

[0011] For clarity of explanation, Fig. 1 shows a three-dimensional orthogonal coordinate system of XYZ. The Z direction is the vertical direction. Therefore, the Z direction is the height direction. The resin is injected, for example, in the negative direction of the Z axis.

[0012] The die 200 has a cavity for accommodating the core 10. For example, a pair of E-shaped cores 10 are inserted into the cavity. The core 10 may be a sintered product obtained by sintering a green compact.

[0013] Fig. 2 is a schematic top view showing the configuration of the core 10. The core 10 includes a base core 11, a center leg core 12, and outer leg cores 13a and 13b. Hereinafter, when the outer leg cores 13a and 13b are not distinguished from each other, they may be simply referred to as the outer leg core 13. The center leg core 12 and the outer leg core 13 protrude in the same direction from the base core 11. In Fig. 2, the X direction is the extension direction of the base core 11, and the Y direction is the extension direction of the center leg core 12 and the outer leg core 13. A coil mold 20 molded with resin is attached to the center leg core 12.

[0014] The base core 11 includes a connection portion 111a that connects the center leg core 12 and the outer leg core 13a, and a connection portion 111b that connects the center leg core 12 and the outer leg core 13b. Hereinafter, when the connection portions 111a and 111b are not distinguished from each other, they may be simply referred to as the connection portion 111.

[0015] The width (e.g., the length in the X direction) of outer leg cores 13a and 13b is narrower than the width of center leg core 12. When manufacturing a smaller size reactor, outer leg core 13 becomes thinner, and there is a possibility that outer leg core 13 may break during molding.

[0016] Returning to FIG. 1, the explanation will be continued. The resin flow path during molding includes inner flow paths 31a and 31b passing through the inside of the core 10, an outer flow path 32 passing through the outside of the core 10, a flow path 33 passing through the inside of the coil mold 20, and a flow path 34 passing between the two cores 10. In the following, when the inner flow paths 31a and 31b are not distinguished from each other, they may be simply referred to as the inner flow path 31. Also, when the inner flow path 31, the outer flow path 32, the flow path 33, and the flow path 34 are not distinguished from each other, they may be simply referred to as the flow path 30. In the related mold 200, the resin is preferentially injected into the outer flow path 32. Therefore, the core 10 is pressurized from the outside to the inside as shown by the arrow, which causes a problem that the core 10 is cracked.

[0017] FIG. 3 is a schematic diagram showing the dimensional relationship between the outer flow path 32 and the inner flow path 31a in the mold 200. In the related 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 such a case, the outer leg 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 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 downward arrow. Since the mold 200 does not have a mechanism for supporting the core 10 against the resin pressure, high stress is generated in the core 10, which may cause it to crack.

[0018] In order to prevent cracking of the core 10, the inventors have studied the relationship between the dimensions of each flow path 30 and the cracking modes of the core 10. FIG. 4 is a schematic diagram showing three cracking modes of the core 10. Mode 1 occurs when resin is filled from the outer flow path 32 first. In mode 1, the outer leg core 13 is pressurized in the X direction as shown by the arrow, and high stress occurs in part X1. The cause of mode 1 is thought to be the lack of a support mechanism inside the outer leg core 13.

[0019] Mode 2 also occurs when the resin is filled first from the outer flow passage 32. In mode 2, the base core 11 is pressurized in the Y direction as shown by the arrow, and high stress occurs in the part X2. The cause of mode 2 is thought to be the lack of a support mechanism inside the base core 11.

[0020] Mode 3 occurs when the resin is filled from the top side of the core 10 first. In mode 3, the core 10 is pressurized downward as shown by the arrow, and high stress occurs in part X3. A possible cause of mode 3 is the absence of a support mechanism on the bottom side of the core 10 (e.g., the negative Z-axis direction side).

[0021] Based on the above-mentioned studies, the inventors of the present application have come up with the invention according to the embodiment. The present invention will be described below through the embodiment of the invention, but the invention according to the claims is not limited to the following embodiment. Furthermore, not all of the configurations described in the embodiment are necessarily essential as means for solving the problem.

[0022] EMBODIMENT 1 Hereinafter, the manufacturing apparatus according to the embodiment 1 will be described with reference to the drawings. Fig. 5 is a schematic top view showing an overview of a mold 100 of the manufacturing apparatus according to the embodiment 1. The following description will focus on the differences from the mold 200 of the related manufacturing apparatus described above.

[0023] The mold 100 includes core support pins 110a, 110b, 110c, 110d, 110e, 110f, and 110g. Hereinafter, when the core support pins 110a, 110b, 110c, 110d, 110e, 110f, and 110g are not to be distinguished from one another, they may be simply referred to as core support pins 110. Since resin does not flow into the portion in contact with the core support pins 110, windows corresponding to the core support pins 110 are formed in the molded product.

[0024] The core support pins 110 contact the core 10 and support the core 10 against the resin pressure during molding. The core support pins 110a, 110b, 110c, and 110d support the outer leg core 13 against the resin pressure during molding indicated by the arrows in the ±X directions. The core support pins 110e, 110f, and 110g support the base core 11 against the resin pressure during molding indicated by the arrows in the ±Y directions. The downward arrows indicate that the resin pressure is received from both of the two inner flow paths 31. The core support pins 110e and 110f support the connection portion 111 included in the base core 11.

[0025] The core support pins 110a, 110b, 110c, 110d, 110e, and 110f are disposed at positions where the width of the inner flow passage 31 is wider than that of the outer flow passage 32. Note that some of the core support pins 110 (for example, the core support pin 110e) may be disposed at other positions.

[0026] 6 is a schematic diagram showing the dimensional relationship between the outer flow passage 32 and the inner flow passage 31a in the mold 100. The outer flow passage 32 includes a flow passage on the outer side of the outer leg core 13a. The inner flow passage 31a includes a flow passage in the gap between the coil mold 20 and the outer leg core 13a.

[0027] In the mold 100, the width W2 in the X direction of the inner flow passage 31a is wider than the width W1 in the X direction of the outer flow passage 32. In other words, the width of the above-mentioned gap is wider than the width of the flow passage outside the outer leg core 13a. In such a case, the outer leg core 13a of the core 10 is pressurized in the direction indicated by the left arrow. The core support pin 110a supports the outer leg core 13a against the pressure in the direction of the left arrow, preventing deformation of the outer leg core 13a.

[0028] Similarly, the width of the inner flow passage 31a in the Y direction is greater than the width of the outer flow passage 32 in the Y direction. Therefore, the base core 11 of the core 10 is pressurized in the direction indicated by the upward arrow. The core support pin 110f supports the base core 11 against the pressure in the direction indicated by the upward arrow, preventing the base core 11 from being deformed.

[0029] The mold 100 is designed so that the width of the inner flow path 31 is wider than the width of the outer flow path 32, and can prevent the core 10 from deforming inward and cracking. Furthermore, the core 10 is supported from the outside by the core support pins 110, and the mold 100 can prevent the core 10 from deforming outward and cracking. Therefore, the manufacturing apparatus according to the first embodiment can prevent the core 10 from cracking due to the resin pressure during molding.

[0030] Next, with reference to Figs. 7 to 9, a preferred dimensional relationship between the flow paths 30 will be described. Figs. 7 to 9 are diagrams showing a preferred dimensional relationship between the flow paths 30. Note that the core support pins 110 are omitted from Figs. 7 to 9. Reference A in Fig. 7 indicates the width of the inner flow path 31 in the X direction. Reference B in Fig. 7 indicates the width B of the outer flow path 32 in the X direction. Reference C in Fig. 8 indicates the width of the inner flow path 31 in the Y direction. Reference D in Fig. 8 indicates the width of the outer flow path 32 in the Y direction. Reference H in Fig. 9 indicates the width of the flow path 34 described above. The inventors have discovered that by satisfying the following first to third dimensional relationships, it is possible to prevent cracking due to the above-mentioned modes 1 to 3.

[0031] 7, the first dimensional relationship is that A>B and 0.5≦B≦2 (unit: mm) are satisfied. In relation to the above-mentioned mode 1, the width in the X direction of the inner flow path 31 is set to be wider than the width in the X direction of the outer flow path 32. The width in the X direction of the outer flow path 32 can be selected from the range of 0.5 mm or more and 2 mm or less.

[0032] 8, the second dimensional relationship is that C>D and 0.5≦D≦2 (unit: mm) are satisfied. In relation to the above-mentioned mode 2, the width in the Y direction of the inner flow passage 31 needs to be set wider than the width in the Y direction of the outer flow passage 32. In relation to the above-mentioned mode 3, the width in the Y direction of the outer flow passage 32 needs to be appropriately set.

[0033] 9, the third dimensional relationship is that 0.4≦H≦2 (unit: mm) is satisfied, and at least one of the outer leg cores 13a contact each other and the outer leg cores 13b contact each other. In relation to the above-mentioned modes 2 and 3, the width of the flow path 34 needs to be selected from the range of 0.4 mm or more and 2 mm or less.

[0034] The manufacturing device according to the first embodiment makes the dimensions of the inner flow passage wider than the outer flow passage, so that resin is poured first inside the core 10, and the core subjected to resin pressure is supported by pins provided in the mold. Therefore, the manufacturing device according to the first embodiment can prevent the core 10 from cracking by suppressing deformation of the core and reducing stress inside the core.

[0035] The present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit and scope of the present invention. [Explanation of symbols]

[0036] 10 cores 11. Bass Core 111, 111a, 111b connection parts 12 Mid-leg core 13, 13a, 13b Outer leg core 20 Coil mold 30 Flow Path 31, 31a, 31b Inner flow passage 32 Outer channel 33, 34 Flow path 100 Molds 200 Molds 110, 110a, 110b, 110c, 110d, 110e, 110f, 110g Core support pin h Insertion hole

Claims

1. An apparatus for manufacturing a reactor having a core, comprising: A mold having a cavity for accommodating the core, the die includes a core support pin that contacts the core and supports the core against resin pressure during molding; a resin flow path during molding includes an inner flow path passing through the inside of the core and an outer flow path passing through the outside of the core; The core support pin is disposed at a position where the width of the inner flow passage is wider than the width of the outer flow passage, The manufacturing apparatus is an apparatus for manufacturing a reactor including a pair of E-shaped cores, Each E-shaped core includes an outer leg core and a center leg core protruding in the same direction from a base core, The width of the outer leg core is smaller than the width of the center leg core, The core support pin supports the outer leg core against resin pressure in a direction perpendicular to a direction in which the outer leg core protrudes from the base core. Reactor manufacturing equipment.

2. A coil mold made of resin is attached to the center leg core, The inner flow passage includes a flow passage in a gap between the coil mold and the outer leg core, the outer flow passage includes a flow passage on the outer side of the outer leg core, The width of the gap is wider than the width of the flow passage on the outside of the outer leg core. An apparatus for manufacturing the reactor according to claim 1 .

3. A method for manufacturing a reactor including a core, comprising the steps of: forming a molded article using a mold having a cavity for receiving the core; the die includes a core support pin that contacts the core and supports the core against resin pressure during molding; The resin flow path in the molding step includes an inner flow path passing through the inside of the core and an outer flow path passing through the outside of the core, The core support pin is disposed at a position where the width of the inner flow passage is wider than the width of the outer flow passage, The manufacturing method is a method for manufacturing a reactor including a pair of E-shaped cores, Each E-shaped core includes an outer leg core and a center leg core protruding in the same direction from a base core, The width of the outer leg core is smaller than the width of the center leg core, The core support pin supports the outer leg core against resin pressure in a direction perpendicular to a direction in which the outer leg core protrudes from the base core. A method for manufacturing a reactor.

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