Mold Coil and Reactor, and Method for Manufacturing Mold Coil and Method for Manufacturing Reactor

Abstract

To provide a molded coil and a reactor capable of suppressing the generation of burrs even when an upper cover abutting on a lower mold is provided.SOLUTION: A molded coil formed by molding a coil with a molding resin includes an upper cover 31 provided on the upper surface of a coil 2. The upper cover 31 includes an upper surface covering portion 311 that covers the upper surface of the coil 2, a lower mold contact portion 312 that contacts the lower mold during molding, and a flexible portion 313 made of an elastic member connecting the upper surface covering portion 311 and the lower mold contact portion 312. The flexible portion 313 bends when the upper mold is pressed against the bottom surface of the coil 2 during molding.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to a molded coil molded with resin and a reactor provided with the molded coil.

Background Art

[0002] In recent years, resin mold type molded coils in which the outer periphery of a coil is coated with resin have been used in various places. A molded coil is formed by placing a coil at a predetermined position in a mold and injecting resin into the mold. However, since a coil is formed by winding a conducting wire, its dimensions may vary, a gap may occur between the coil and the mold, and resin may flow in from the gap, resulting in burrs. Note that burrs are resin that has solidified in the parting surface, grooves of the mold, or gaps between the mold and the molded product.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In order to suppress the generation of burrs, a method is adopted in which the mold is strongly pressed against the coil to correct the dimensional variation of the coil and bring the coil and the mold into close contact without a gap. However, when the coil is directly pressed by the mold, problems such as damage to the coil, such as breakage of the insulating coating of the conducting wire, occur.

[0005] Therefore, a method is known in which a cover is provided on the outer periphery of the coil and the coil is pressed through the cover. The cover is often divided into an upper cover disposed on the upper surface of the coil and contacting the upper mold and a lower cover disposed on the bottom surface of the coil and contacting the lower mold. By pressing the upper cover against the coil toward the bottom surface with the mold, the cover and the coil and the cover and the mold are brought into close contact without a gap.

[0006] In particular, in recent years, covers of various shapes have emerged, and there are cases where the upper cover abuts not only against the upper mold but also against the lower mold. In such a case, even if the upper cover is pressed, due to its contact with the lower mold, the repulsive force against the pressing force is strong, and it is impossible to closely contact and abut the cover with the coil or the cover with the mold, which may cause burrs.

[0007] The present invention has been made to solve the above problems, and an object thereof is to provide a mold coil and a reactor capable of suppressing the generation of burrs even in the case of having an upper cover that also abuts against the lower mold.

Means for Solving the Problems

[0008] The mold coil of the present invention , C includes an upper cover provided on the upper surface of the coil, and the upper cover has an upper covering portion that covers the upper surface of the coil, and an end face covering portion that covers a part of the end face of the coil orthogonal to the winding axis direction, and an edge forming portion disposed below the end face covering portion , a bent portion formed of an elastic member that connects the upper covering portion and the End face covering portion and, and is characterized by having the above. Further, the method for manufacturing a molded coil of the present invention is a method for manufacturing a molded coil in which a coil is molded with a molding resin, and includes an upper cover mounting step of mounting an upper cover on the upper surface of the coil, a pressing step of housing the coil with the upper cover mounted therein in a mold and pressing the upper cover from the upper surface of the coil toward the bottom surface with the upper mold of the mold, and a molding step of injecting the molding resin into the mold and covering at least a part of the coil with the molding resin. The upper cover has an upper surface covering portion that covers the upper surface of the coil, a lower mold contact portion that contacts the lower mold during the molding, and a bending portion formed of an elastic member that connects the upper surface covering portion and the lower mold contact portion.

[0009] Further, a reactor including the above mold coil, a core on which the mold coil is mounted on the outer periphery, and a secondary mold resin portion that covers the outer peripheries of the mold coil and the core is also an aspect of the present invention. Furthermore, the above mold coil The molded coil manufactured by the manufacturing method is on the outer periphery of the core A method for manufacturing a reactor including a core mounting step of mounting the core and a double molding step of covering the outer peripheries of the mold coil and the core with a secondary mold resin portion is also an aspect of the present invention.

Advantages of the Invention

[0010] According to the present invention, it is possible to obtain a mold coil and a reactor capable of suppressing the generation of burrs even in the case of having an upper cover that also abuts against the lower mold.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

MODE FOR CARRYING OUT THE INVENTION

[0012] (Reactor) The reactor according to this embodiment will be described with reference to the drawings. FIG. 1 is a perspective view showing the overall configuration of the reactor. FIG. 2 is a perspective view showing the overall configuration of the mold coil. FIG. 3 is a perspective view of the mold coil as seen from the bottom surface. FIG. 4 is a perspective view showing the state where the upper cover and the lower cover are attached to the coil.

[0013] The reactor 100 of this embodiment includes a mold coil 1 and a core 5. The mold coil 1 is formed by coating a coil 2 with a mold resin portion 4 by means of mold molding. The core 5 has the mold coil 1 mounted thereon. The core 5 forms a closed magnetic circuit through which the magnetic flux generated by the coil 2 passes. That is, the reactor 100 is an electromagnetic component that converts electrical energy into magnetic energy for storage and release, and is used in drive systems of hybrid vehicles, electric vehicles, etc.

[0014] The reactor 100 is mold-molded with a secondary mold resin portion 6 and is a so-called double-mold-structured reactor in which the mold coil 1 and the core 5 are fixed. The secondary mold resin portion 6 covers the outer periphery of the mold coil 1 and the core 5 and fixes the mold coil 1 and the core 5.

[0015] (Mold Coil) In this embodiment, two mold coils 1 are provided. The mold coils 1 are arranged side by side with a gap therebetween so as to be parallel to the winding axis direction of the coils. The mold coils 1 are mounted on the legs of the core 5. As shown in FIG. 2, the mold coil 1 has a coil 2, a cover 3, and a mold resin portion 4.

[0016] The coil 2 is composed of a single flat conductive member insulated and coated with enamel or the like. The coil 2 is formed by winding a wire while shifting the winding position in the winding axis direction. In this embodiment, it is an edgewise coil of a flat wire made of a copper wire. However, the type of wire and the winding method of the coil 2 are not limited to this, and other forms may be used.

[0017] The bottom surface of the coil 2 has an opening 21 that is not covered by the mold resin portion 4 and is exposed (see FIG. 3). The opening 21 is generally rectangular in shape. Note that, for the coil 2, lead wires that are ends of the conductive member extend along the winding axis direction of the coil 2.

[0018] Note that the up-down direction follows the upper mold and the lower mold that accommodate the coil 2 during mold forming, and does not refer to the positional relationship and direction when the reactor 100 is installed on the actual machine to be installed. That is, the bottom surface of the coil 2 refers to the end surface where the lower cover 32 described later is disposed, and the end surface facing the bottom surface of the coil 2 becomes the upper surface of the coil 2. Also, both end surfaces orthogonal to the winding axis direction of the coil 2 are also referred to as core insertion surfaces, and the end surface parallel to the winding axis direction of the coil 2 and connecting the upper surface and the bottom surface of the coil 2 is also referred to as the side surface of the coil 2.

[0019] The cover 3 is provided on the outer periphery of the coil 2. The cover 3 has an upper cover 31 disposed on the upper surface of the coil 2 and a lower cover 32 disposed on the bottom surface of the coil 2. FIG. 5 is a perspective view showing the configuration of the upper cover 31. As shown in FIG. 5, the upper cover 31 has an upper surface covering portion 311, a lower mold abutting portion 312, and a bending portion 313. Note that the upper surface covering portion 311, the lower mold abutting portion 312, and the bending portion 313 are integrally formed.

[0020] The upper surface covering portion 311 covers the upper surface of the coil 2. In the present embodiment, the upper surface covering portion 311 covers the entire upper surface of the coil 2. This upper surface covering portion 311 abuts against the upper mold during mold forming. Also, the upper surface covering portion 311 covers a part of one of the core insertion surfaces of the coil 2 and a part of both side surfaces of the coil 2.

[0021] The lower mold abutting portion 312 has an end surface covering portion 312a and an edge forming portion 312b. The end surface covering portion 312a covers a part of the end surface of the coil 2 orthogonal to the winding axis direction. The edge forming portion 312b is disposed below the end surface covering portion 312a and forms the edge of the rectangular opening 21 of the coil 2. The edge forming portion 312b abuts against the lower mold during mold forming. The end surface covering portion 312a and the edge forming portion 312b are fitted with the lower cover 32. However, the fitting here does not mean that they are completely fixed, but means that they are fitted so as to be movable in the axial direction of the coil 2.

[0022] The flexing portion 313 is a rod-shaped member that connects the upper surface covering portion 311 and the lower mold abutting portion 312. The flexing portion 313 is provided on the side surface of the coil 2. The flexing portion 313 flexes due to the pressing force from the upper mold during mold molding. Therefore, the flexing portion 313 preferably consists of a member having elasticity that can be deformed by the pressing force of the mold. For example, polyester-based, styrene-based, olefin / alkene-based, PVC-based, urethane-based, amide-based elastomers, such as epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Terephthalate), etc. can be mentioned. In the present embodiment, the flexing portion 313 is made of PPS (Polyphenylene Sulfide).

[0023] FIG. 6 is an enlarged view of the flexing portion 313. As shown in FIG. 6, the flexing portion 313 has a straight portion 314 and curved portions 315a, 315b. The straight portion 314 extends along the winding axis direction of the coil 2. As will be described later, during mold molding, the resin is injected along the winding axis direction, so the straight portion 314 extends along the injection direction of the resin.

[0024] The curved portions 315a, 315b are connected to the straight portion 314 and are bent approximately 90 degrees. The curved portion 315a is connected to the straight portion 314, bent 90 degrees, and connected to the upper surface covering portion 311. The curved portion 315b is connected to the straight portion 314, bent 90 degrees, and connected to the lower mold abutting portion 312. Thus, the flexing portion 313 of the present embodiment has a substantially S-shaped configuration including curved portions, and is in a shape that is easily flexed by the pressing force from the upper mold.

[0025] Also, the flexing portion 313 has a resin inlet 316. The resin inlet 316 is an opening through which the resin that constitutes the mold resin portion 4 flows in during mold molding. The resin inlet 316 extends in a direction orthogonal to the injection direction of the resin.

[0026] In the present embodiment, two resin inlets 316 are provided. The resin inlet 316a allows resin to flow into the space defined by the straight portion 314, the curved portion 315a, and the upper covering portion 311. The resin inlet 316b allows resin to flow into the space defined by the straight portion 314, the curved portion 315b, and the lower cover 32 (see FIG. 4).

[0027] The lower cover 32 abuts against the lower mold during mold forming. That is, the lower cover 32 is provided on the bottom surface of the coil 2. However, the lower cover 32 does not entirely cover the bottom surface of the coil 2. The lower cover 32 has a substantially U-shaped configuration with one side of a rectangle missing, and forms the edge of the opening 21 of the coil 2. At the location where one side of the rectangle is missing, the edge forming portion 312b of the lower mold abutting portion 312 fits, thereby forming a frame body, and the edge of the opening 21 is formed by the lower cover 32 and the edge forming portion 312b.

[0028] The molded resin portion 4 covers the coil 2, the upper cover 31, and the lower cover 32. The coil 2, the upper cover 31, and the lower cover are integrally fixed by the molded resin portion 4 by mold forming. However, the molded resin portion 4 does not cover the bottom surface of the coil 2, and the bottom surface of the coil 2 is exposed.

[0029] A gate (not shown) is provided in the molded resin portion 4. The gate indicates the position where resin is injected into the mold during mold forming. The gate is provided on the end face of the molded resin portion 4 that is orthogonal to the winding axis direction of the coil 2. That is, the resin constituting the molded resin portion 4 is injected along the winding axis direction of the coil 2. Further, the gate is provided on the extension line in the winding axis direction of the end face of the upper cover 31 that is orthogonal to the winding axis direction of the coil 2. That is, the resin injected during mold forming is injected toward the end face.

[0030] Examples of the type of resin constituting the molded resin portion 4 include epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Terephthalate), and the like. In particular, it is desirable to use a resin with high thermal conductivity. By using a resin with high thermal conductivity, the heat of the coil 2 can be transferred to the outside.

[0031] (Core) The core 5 is a magnetic material such as a powder core, a ferrite core, a laminated steel plate, or a metal composite. The metal composite core is a core formed by kneading and molding magnetic powder and resin. The core 5 is composed of a pair of U-shaped core blocks. The core 5 forms an annular shape by butting the legs of the pair of U-shaped core blocks 21 against each other and joining them with an adhesive or the like.

[0032] (Secondary Molded Resin) As shown in FIG. 1, the secondary molded resin portion 6 covers the outer peripheries of the molded coil 1 and the core 5 by mold molding, and fixes the molded coil 1 and the core 5. Note that the reactor 100 of the present embodiment includes a sensor 7 and is fixed by the secondary molded resin portion 6. Note that, as the type of resin constituting the secondary molded resin portion 6, the same resin as that of the molded resin portion 4 can be used.

[0033] (Operation) When manufacturing the molded coil 1 of the present embodiment, first, the coil 2 with the upper cover 31 and the lower cover 32 attached is set in the lower mold. Then, the upper mold is covered over the upper surface covering portion 311 of the upper cover 31.

[0034] Here, since the coil 2 is formed by winding a wire in one direction, there are variations in the dimensions of the coil 2, and gaps may occur between the coil 2 and the cover 3. Then, resin may enter through the gap, resulting in burrs.

[0035] Therefore, in order to closely attach the coil 2 and the cover 3, the upper mold is strongly pressed from the upper surface to the bottom surface of the coil 2 to correct the dimensions of the coil 2. At this time, since the bending portion 313 made of a rod-shaped elastic member bends, the upper surface covering portion 311 comes into close contact with the upper surface of the coil 2. Further, when the upper mold is further pressed with the upper surface covering portion 311 in close contact with the upper surface of the coil 2, the pressing force is transmitted to the lower cover 32 through the upper surface covering portion 311 and the coil 2, and the bottom surface of the coil 2 and the lower cover 32, and the lower cover 32 and the lower mold come into close contact and abut.

[0036] The bending portion 313 connects the upper surface covering portion 311 and the lower mold abutting portion 312. Therefore, the pressing force from the upper mold is also transmitted to the lower mold abutting portion 312 through the upper surface covering portion 311 and the bending portion 313. Therefore, the edge forming portion 312b of the lower mold abutting portion 312 comes into close contact and abuts against the lower mold. In this way, resin is injected with the upper cover 31 and the coil 2, the lower mold and the lower cover 32, and the edge forming portion 312b in close contact. Therefore, the edge forming portion 312b and the lower cover 32 and the lower mold prevent the inflow of resin, and an opening 21 is formed on the bottom surface of the coil 2.

[0037] Further, the bending portion 313 has a substantially S-shaped shape having curved portions 315a and 315b. Therefore, it is easier to bend than when it is bent at a right angle, so the upper cover 31 and the coil 2, the lower mold and the lower cover 32, and the edge forming portion 312b can be made to adhere more closely. Further, when it is bent at a right angle, corners are formed, but it is difficult for resin to be filled in the corners. On the other hand, the bending portion 313 of the present embodiment has a curved shape and no corners are formed. Therefore, the resin is filled up to every corner of the bending portion 313.

[0038] In particular, the bending portion 313 has resin inlets 316a and 316b that extend in a direction orthogonal to the resin injection direction. Therefore, the resin easily flows into the inside of the bending portion 313, that is, the space defined by the straight portion 314, the curved portion 315a or 315b, and the upper surface covering portion 311 or the lower cover 32 from the resin inlets 316a and 316b. Therefore, the resin is filled up to every corner of the bending portion 313.

[0039] The end face covering portion 312a and the edge forming portion 312b are engaged with the lower cover 32 so as to be movable in the axial direction of the coil 2. Then, the resin is injected toward the end face of the upper cover 31 that is orthogonal to the winding axis direction of the coil 2. Since the upper cover 31 is integrally formed and is made of a member having deformable elasticity like the bending portion 313, it deforms under the injection pressure of the resin. Therefore, the end face covering portion 312a and the edge forming portion 312b press the coil 2 in the winding axis direction. Thus, variations in the dimensions of the coil 2 in the winding axis direction can also be corrected.

[0040] (Effect) As described above, the molded coil 1 of the present embodiment includes an upper cover 31 provided on the upper surface of the coil 2. The upper cover 31 has an upper surface covering portion 311 that covers the upper surface of the coil 2, a lower mold contact portion 312 that contacts the lower mold during molding, and a bending portion 313 formed of an elastic member that connects the upper surface covering portion 311 and the lower mold contact portion 312.

[0041] Thereby, when pressing toward the bottom surface of the coil 2 with the upper mold during molding, the bending portion 313 bends, and the upper surface covering portion 311 and the upper surface of the coil 2 come into close contact and contact. Also, the force pressed by the upper mold is transmitted to the lower mold contact portion 312 via the bending portion 313. Therefore, since the lower mold contact portion 312 is also pressed toward the lower mold, the lower mold contact portion 312 and the lower mold come into close contact and contact. Thus, even if there are variations in the dimensions of the coil 2 in the height direction, the variations can be corrected, and the generation of burrs can be suppressed.

[0042] The bottom surface of the coil 2 has an opening 21 exposed from the molded resin portion 4, and the molded coil 1 further includes a lower cover 32 including a portion that becomes the edge of the opening 21. And the lower mold contact portion 312 is engaged with the lower cover 32 and is formed as a part of the edge of the opening 21.

[0043] When an opening 21 is provided on the bottom surface of the coil 2, if the lower mold, the lower cover 32, and the lower mold contact portion 312 do not adhere closely and there is a gap, resin may flow in from the gap, resulting in the generation of burrs. However, in this embodiment, by having the bending portion 313, the upper cover 31 and the coil 2 are in close contact. Then, by further pressing the upper mold in the close contact state, this pressing force is transmitted to the lower cover 32 through the coil 2, and the lower cover 32 and the lower mold are in close contact without a gap. Also, through the upper surface covering portion 311 and the bending portion 313, the pressing force from the upper mold is transmitted to the lower mold contact portion 312, so the lower mold contact portion 312 and the lower mold are also in close contact. Therefore, it is possible to suppress the generation of burrs at the opening 21. Also, since the opening 21 can be formed with high precision, the heat dissipation performance of the mold coil 1 is also improved.

[0044] The bending portion 313 includes curved portions 315a and 315b and is configured in a substantially S-shaped form. In this way, the bending portion 313 includes a curved shape and has no corners. Therefore, the bending portion 313 is easily bent, and the upper surface of the coil 2, the upper cover 31, the lower mold contact portion 312, and the lower cover 32 and the lower mold can be more effectively adhered. Also, since no corners are formed in the bending portion 313, the resin is easily filled to every corner, improving the moldability of the resin mold.

[0045] The bending portion 313 has a resin inlet 316 that extends in a direction orthogonal to the resin injection direction during mold molding. In this way, since the bending portion 313 has the resin inlet 316 that extends in the resin injection direction, the inside of the bending portion 313 is easily filled with resin, improving the moldability of the resin mold.

[0046] The flexing portion 313 is made of PPS (Polyphenylene Sulfide). As described above, since the flexing portion 313 is flexed by the pressing of the upper mold, it is necessary to have elasticity. However, during the mold forming, the temperature exceeds 100 °C and becomes high. Therefore, if the flexing portion 313 does not have heat resistance, the flexing portion 313 may be deformed during the mold forming, and the lower mold, the lower cover 32, and the lower mold abutting portion 312 that are closely attached may be separated, resulting in a gap. However, PPS has elasticity and heat resistance. Therefore, the flexing portion 313 will not be deformed by the heat during the mold forming. Thus, the variation in the dimensions of the coil 2 can be corrected, and the occurrence of burrs can be suppressed.

[0047] Further, the reactor 100 of the present embodiment is a so-called double mold structure reactor including a mold coil 1, a core 5 on which the mold coil 1 is mounted on the outer periphery, and a secondary mold resin portion 6 covering the outer periphery of the mold coil 1 and the core 5.

[0048] As described above, even if there is a variation in the dimensions of the coil 2, after correcting it, since it is mold formed, the moldability is improved, and the dimensional accuracy of the mold coil 1 is also improved. For example, if there is a variation in the dimensions of the mold coil 1, it is necessary to perform operations such as considering the variation in the dimensions and arranging them in the mold during the secondary molding. However, since the mold coil 1 of the present embodiment is formed with good dimensional accuracy, the workability during the secondary molding is improved.

[0049] (Other embodiments) In this specification, the embodiments according to the present invention have been described, but this embodiment is presented as an example and is not intended to limit the scope of the invention. The above-described embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. The embodiments and their modifications are included in the scope and gist of the invention, and are also included in the invention described in the claims and its equivalent scope.

[0050] The flexure portion 313 of this embodiment had a substantially S-shaped configuration having two curved portions 315a and 315b, but the shape of the flexure portion 313 is not limited thereto. For example, as shown in FIG. 7, the flexure portion 313 may have a substantially U-shaped configuration that connects the upper surface covering portion 311 and the lower mold abutting portion 312 (end surface covering portion 312a) with one curve. Even with such a shape, the flexure portion 313 is easily flexed. Further, since no corner portions are formed in the flexure portion 313, the resin is filled up to the corners, improving the moldability.

[0051] Further, the flexure portion 313 is not limited to a curved shape such as a substantially S-shaped configuration or a substantially U-shaped configuration. For example, as shown in FIG. 8, it may have a shape that does not have a curved shape but bends at a right angle. However, in the case of a right-angled shape, stress concentrates at the corner portions, so a curved shape such as a substantially S-shaped configuration or a substantially U-shaped configuration has better durability.

[0052] The flexure portion 313 of this embodiment was provided on the side surface of the coil 2. However, as shown in FIG. 9, it may be provided on the end surface in the winding axis direction of the coil 2, connecting the upper surface covering portion 311 and the lower mold abutting portion 312.

[0053] Further, as shown in FIG. 9, the flexure portion 313 may be provided on each of the side surface and the end surface of the coil 2. Thus, when the number of flexure portions 313 is increased, the strength of the flexure portions 313 is improved. Therefore, the pressing force by the upper mold can be made stronger, and the cover 3, the mold, and the coil 2 can be brought into closer contact with each other, so that the generation of burrs can be more effectively suppressed.

[0054] The coil 2 had an opening 21 on the bottom surface, but an opening may also be provided on the upper surface. In this case, the portion of the upper surface covering portion 311 that covers the upper surface of the coil 2 may be formed in a frame shape, such as the lower cover 32 and the edge forming portion 312b, to cover only the edge portion of the upper surface of the coil 2.

Description of Reference Numerals

[0055] 100 Reactor 1 Mold Coil 2 Coil 21 Opening 3 Cover 31 Upper Cover 311 Upper Covering Portion 312 Lower Mold Contact Portion 312a End Face Covering Portion 312b Edge Forming Portion 313 Deflection Portion 314 Straight Portion 315 Curved Portion 316 Resin Inlet 32 Lower Cover 4 Mold Resin 5 Core 6 Secondary Mold Resin 7 Sensor

Claims

1. comprising an upper cover provided on the upper surface of the coil; said upper cover an upper covering portion covering the upper surface of the coil; an end surface covering portion covering a part of the end surface of the coil orthogonal to the winding axis direction; an edge forming portion disposed below the end surface covering portion; and a bending portion composed of an elastic member connecting the upper covering portion and the end surface covering portion; having A molded coil characterized by the above.

2. The bottom surface of the coil has an opening exposed from the molded resin, further comprising a lower cover including a portion that forms an edge of the opening; said edge forming portion being fitted with the lower cover and formed as a part of the edge of the opening; The molded coil according to claim 1, characterized by the above.

3. said bending portion including a curved shape; The molded coil according to claim 1 or 2, characterized by the above.

4. said bending portion being generally S-shaped; The molded coil according to any one of claims 1 to 3, characterized by the above.

5. said bending portion being made of PPS (Polyphenylene Sulfide); The molded coil according to any one of claims 1 to 4, characterized by the above.

6. A molded coil according to any one of claims 1 to 5; a core on which the molded coil is mounted on the outer periphery; and a secondary molded resin portion covering the outer peripheries of the molded coil and the core; comprising A reactor characterized by the above.

7. A method for manufacturing a molded coil in which a coil is molded with a molding resin, an upper cover mounting step of mounting an upper cover on the upper surface of the coil, a pressing step of housing the coil with the upper cover mounted therein in a mold and pressing the upper cover from the upper surface to the bottom surface of the coil with the upper mold of the mold, a molding step of injecting the molding resin into the mold and covering at least a part of the coil with the molding resin, including the upper cover has an upper surface covering portion that covers the upper surface of the coil, a lower mold contact portion that contacts the lower mold during the molding, and a bending portion composed of an elastic member that connects the upper surface covering portion and the lower mold contact portion, having in the pressing step, by pressing the upper cover with the upper mold, the bending portion bends, A method for manufacturing a molded coil, characterized in that.

8. In the molding step, the molding resin does not cover the bottom surface of the coil so that an opening is formed in the bottom surface of the coil, further comprising a lower cover including a portion that becomes an edge of the opening, the lower mold contact portion fits with the lower cover and is formed as a part of an edge of the opening, The method for manufacturing a molded coil according to claim 7, characterized in that.

9. The bending portion includes a curved shape, The method for manufacturing a molded coil according to claim 7 or 8, characterized in that.

10. The bending portion has a substantially S-shaped shape, The method for manufacturing a molded coil according to any one of claims 7 to 9, characterized in that.

11. The bent portion has a resin inlet that extends in a direction perpendicular to the resin injection direction during mold molding. The method for manufacturing a mold coil according to any one of claims 7 to 10, characterized by the above.

12. The bent portion is made of PPS (Polyphenylene Sulfide). The method for manufacturing a mold coil according to any one of claims 7 to 11, characterized by the above.

13. A core mounting step of mounting a mold coil manufactured by the method for manufacturing a mold coil according to any one of claims 7 to 12 on the outer periphery of a core, A double molding step of covering the outer periphery of the mold coil and the core with a secondary molded resin portion, Including the above, A method for manufacturing a reactor, characterized by the above.

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