Reactor parts and method for manufacturing the same

Abstract

To provide a reactor component capable of preventing a mold resin from being formed in a part of a coil while suppressing an increase in the number of components.SOLUTION: A reactor component comprises: a coil 10; a core 40 which is disposed in a hollow part of the coil; a bobbin which is a positioning member for the coil and the core; and a resin part 50 which integrally covers the coil, the bobbin and the core. The bobbin includes: cylinders 22 and 32 which are disposed in the hollow part; two flanges which are disposed in both ends of the coil; and a pair of connection parts 24 provided so as to span the two flanges. The pair of connection parts includes: a distal end face 243 and an opposed face 244 which hold a part of the coil therebetween and include a portion in contact with an outer wall of the coil from one opening end of the coil to the other opening end; and a resin contact face 245 in contact with the resin part. A part of the held coil is separated from the resin part so as to be exposed from the resin part.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to reactor components and a method for manufacturing the same.

Background Art

[0002] As an example of reactor components, there is one disclosed in Patent Document 1. The reactor component includes a lower frame body disposed on the surface of a coil and a mold resin that covers the coil except within the frame of the lower frame body. The lower frame body has a pair of vertical side portions along the cylindrical axis of the coil. The pair of vertical side portions extend sandwiching the lower surface of the coil and are in close contact with two lower curved surfaces adjacent to the lower surface of the coil. The coil exposes the lower surface of the coil sandwiched by the pair of vertical side portions from the mold resin over the entire width range from one lower curved surface with which the pair of vertical side portions are in close contact to the other lower curved surface.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, for the reactor component, a configuration in which the positioning of the coil and the core is performed by a bobbin is conceivable. In the case of this configuration, in the technique described in Patent Document 1, in addition to the bobbin, a lower frame body is required to prevent the mold resin from being formed on a part of the coil. Therefore, the configuration described in Patent Document 1 has a problem that the number of components increases. From the above viewpoints, or from other viewpoints not mentioned, further improvement of the reactor component is required.

[0005] One of the disclosed objects is to provide a reactor component that can suppress an increase in the number of parts and prevent a mold resin from being formed on a part of the coil. Another disclosed object is to provide a manufacturing method capable of manufacturing a reactor component that can suppress an increase in the number of parts and prevent a mold resin from being formed on a part of the coil.

Means for Solving the Problems

[0006] The reactor component disclosed herein includes a cylindrical coil (10) wound around and having openings at both ends, a core (40) disposed in the hollow portion of the coil, a bobbin (20, 30) that is a positioning member for the coil and the core, and includes cylindrical portions (22, 32) disposed in the hollow portion, two flange portions (21, 31) provided continuously with the cylindrical portions and disposed at both ends of the coil, and a pair of connecting portions (24, 24a, 34a) provided across the two flange portions, and a resin portion (50) integrally covering the coil, the bobbin, and the core. The pair of connecting portions sandwich a part of the coil and have a coil side wall surface (243, 244) including a portion in contact with the outer wall of the coil at at least a part between one opening end and the other opening end of the coil, and a resin side wall surface (245) that is opposite to the coil side wall surface and in contact with the resin portion, and are partitioned from the resin portion so that a part of the sandwiched coil is exposed from the resin portion. and has opposing portions that bend along the curved surface of the outer wall and whose distance between each other becomes narrow, and protruding portions that are continuous with the opposing portions and whose distance between each other becomes wide It is characterized by this.

[0007] Thus, the reactor component includes a bobbin having a connecting portion. The connecting portion of the bobbin has a coil side wall surface and a resin side wall surface, and is partitioned so that a part of the sandwiched coil is exposed from the resin portion. Therefore, the reactor component can prevent a resin portion from being formed on a part of the coil by the bobbin. For this reason, the reactor component can suppress an increase in the number of parts and prevent a resin portion from being formed on a part of the coil.

[0010] In the embodiments disclosed in this specification, different technical means are adopted to achieve their respective purposes. The claims and the reference numerals in parentheses described in this section are for illustrative purposes to show the correspondence with the parts of the embodiments described later, and are not intended to limit the technical scope. The objects, features, and effects disclosed in this specification will become clearer by referring to the subsequent detailed description and the accompanying drawings.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Embodiments for Carrying Out the Invention

[0012] Hereinafter, embodiments for implementing the present disclosure will be described with reference to the drawings.

[0013] <Structure> As shown in FIGS. 1, 2, 3, and 4, the reactor component 100 includes a coil 10, a bobbin (first member 20, second member 30), a core 40, and a resin part 50. The reactor component 100 is used, for example, in a voltage converter that boosts the voltage of a battery in the drive system of an electric vehicle. That is, the reactor component 100 is a circuit element that constitutes a reactor in a voltage converter or the like. The reactor component 100 may be referred to as a coil unit and a coil device.

[0014] The coil 10 is in a state where a winding such as an insulated wire is wound. In the present embodiment, as shown in FIGS. 3 and 4, a rectangular flat wire winding with a relatively small internal resistance is adopted. However, the present disclosure is not limited to this, and a round wire can also be adopted.

[0015] As shown in FIG. 4, the coil 10 is cylindrical with a winding wound around it and having openings at both ends. Therefore, it can also be said that the coil 10 has a hole 12 surrounded by the winding. A part of the bobbin and a part of the core 40 are arranged in the hole 12. The coil 10 has lead-out parts 11 at both ends as terminals of the reactor component 100.

[0016] Note that the hole 12 corresponds to the hollow part of the coil 10. An imaginary straight line passing through the center of the coil 10 (hole 12) is also referred to as an axis. The axis is an imaginary straight line extending from one opening of the coil 10 to the other opening.

[0017] The coil 10 forms a wall part (outer wall) by arranging windings side by side. The coil 10 has, as the wall part, a bottom wall 13, an upper wall 14 that is opposite to the bottom wall 13, and two side walls 15 that are continuous with the bottom wall 13 and the upper wall 14. Further, the coil 10 has a bent shape (R shape) between the bottom wall 13 and the two side walls 15, and between the upper wall 14 and the two side walls 15. This bent part can also be referred to as a bent portion.

[0018] Note that the bottom wall 13 is a part that is exposed from the resin part 50. Therefore, the bottom wall 13 may also be referred to as an exposed wall. In this case, since the upper wall 14 is the opposite part of the bottom wall 13, it may also be referred to as an opposite wall.

[0019] As shown in FIGS. 2 and 4, etc., the bobbin is formed by assembling and integrating a first member 20 and a second member 30 provided separately. The first member 20 and the second member 30 are made of, for example, resin as the main component. The bobbin is a positioning member for the coil 10 and the core 40. The bobbin can also be said to be a member around which the coil 10 is wound.

[0020] The first member 20 has a flange part 21, a cylindrical part 22, a hole part 23, a connecting part 24, and a base part 25. The cylindrical part 22 and the connecting part 24 project from the flange part 21 in the axial direction. The flange part 21 and the cylindrical part 22 are provided with a hole part 23 in which the core 40 is arranged. The flange part 21 has a substantially rectangular outer shape. In this embodiment, as an example, a flange part 21 having a shape in which the corners of a rectangle are rounded is adopted.

[0021] The cylindrical part 22 is provided continuously with the flange part 21. The cylindrical part 22 is provided with a fixing mechanism with the cylindrical part 32 of the second member 30. The cylindrical part 22 corresponds to a cylindrical part.

[0022] The connecting part 24 is a part that is connected to the second connecting part 34 of the second member 30. The connecting parts 24 are provided in pairs. Therefore, in this embodiment, two connecting parts 24 are provided. The connecting part 24 may be provided integrally with the flange part 21 or the cylindrical part 22, or may be connected by a connecting member or the like.

[0023] The two connecting portions 24 are provided at two adjacent corner portions of the flange portion 21. Further, the two connecting portions 24 are provided at positions that sandwich the bent portion in a state where they are assembled to the coil 10. That is, it can be said that the two connecting portions 24 are provided at both ends of the bottom wall 13. Furthermore, it can be said that the two connecting portions 24 are provided at positions that sandwich the bottom wall 13. The bent portion here is a portion that continues to both ends of the bottom wall 13.

[0024] The paired connecting portions 24 partition the resin portion 50 so that a part of the sandwiched coil 10 is exposed from the resin portion 50. That is, the connecting portion 24 is also a member for preventing the resin portion 50 from being formed on a part of the coil 10. Therefore, the connecting portion 24 may also be referred to as a resin cut portion.

[0025] The connecting portion 24 is connected to the second connecting portion 34 in a state where the first member 20 and the second member 30 are assembled. The connecting portion 24 and the second connecting portion 34 are connected by, for example, welding or fitting. The second connecting portion 34 is provided on the flange portion 31. For this reason, it can be said that the two connecting portions 24 are provided across the two flange portions 21, 31.

[0026] The shape of the connecting portion 24 changes before and after the resin portion 50 is provided. That is, the connecting portion 24 is deformed by the molding pressure during resin molding of the resin portion 50. FIGS. 5 and 8(a) show the connecting portion 24 before the resin portion 50 is provided. FIGS. 3, 7, and 8(b) show the connecting portion 24 after the resin portion 50 is provided. Hereinafter, the state before the resin portion 50 is provided is also referred to as the pre-molding state, and the state after the resin portion 50 is provided is also referred to as the post-molding state. In FIGS. 7 and 8(b), the core 40 and the resin portion 50 are omitted.

[0027] As shown in FIGS. 5 and 8(a), the connecting portion 24 has an opposing portion 241, a protruding portion 242, a tip surface 243, an opposing surface 244, and a resin contact surface 245. The opposing portion 241 is a portion that faces the coil 10. The opposing portion 241 is provided at a position facing the bent portion between the bottom wall 13 and the side wall 15. The protruding portion 242 is a portion that protrudes from one end of the opposing portion 241. The protruding portion 242 protrudes away from the coil 10 with respect to the opposing portion 241. Therefore, it can be said that in the state before molding, the cross-section perpendicular to the axis of the connecting portion 24 has an L shape.

[0028] Also, as shown in FIGS. 3, 7, and 8(b), the connecting portion 24 is deformed by being pressed in the direction in which the opposing portion 241 approaches the coil 10 by the molding pressure. That is, it can be said that the paired connecting portions 24 have an opposing portion 241 that bends along the curved surface of the outer wall and the distance between them becomes narrow, and a protruding portion 242 that is continuous with the opposing portion 241 and the distance between them becomes wide in the state after molding. Further, as shown in FIG. 2, the paired connecting portions 24 have a shape in which the distance between them gradually becomes narrow and then gradually becomes wide as they go from one flange portion 21 to the other flange portion 31. In FIG. 8(b), the molding pressure is indicated by a white arrow.

[0029] Also, as shown in FIG. 5 and the like, the connecting portion 24 has a shape in which the opposing portion 241 is longer than the protruding portion 242. That is, the height of the opposing portion 241 is longer than the length of the protruding portion 242. The height of the opposing portion 241 is the length in the direction along the perpendicular to the bottom wall 13 or the upper wall 14. The length of the protruding portion 242 is the length in the protruding direction with respect to the opposing portion 241. Thereby, the molding pressure is likely to be applied evenly to the connecting portion 24. Also, with respect to the connecting portion 24, the opposing portion 241 is likely to be deformed toward the coil 10 side by the molding pressure.

[0030] The front end face 243 is the face that faces the coil 10 at the tip of the opposing part 241. The front end face 243 is in contact with the bent part between the bottom wall 13 and the side wall 15 in both the state before molding and the state after molding. The front end face 243 is in contact with the bent part from one open end of the coil 10 to the other open end. Preferably, the front end face 243 has a shape along the shape of the bent part in order to improve the adhesion to the bent part.

[0031] The opposing face 244 is continuous with the front end face 243 and is the face that faces the coil 10. The opposing face 244 is separated from the bent part in the state before molding. However, in the state after molding, at least a part of the opposing face 244 is in contact with the bent part from one open end of the coil 10 to the other open end. This is because the opposing part 241 is deformed by the molding pressure. That is, the connecting part 24 bends due to the molding pressure when forming the resin part 50, and a part of the opposing face 244 and the front end face 243 are in contact with the bent part.

[0032] It can be said that the front end face 243 and the opposing face 244 include the parts in contact with the outer wall (bent part) of the coil 10 from one open end of the coil 10 to the other open end in the state after molding. The front end face 243 and the opposing face 244 correspond to the coil side wall faces. Note that the front end face 243 and the opposing face 244 may be in contact with the bent part at least in a part between one open end and the other open end of the coil 10.

[0033] In order to improve the adhesion degree of the front end face 243 and the opposing face 244 to the coil 10, it is preferable that the opposing part 241 is more easily deformed. For this reason, the connecting part 24 may be configured to be thinner in the opposing part 241 than in the protruding part 242.

[0034] The resin contact face 245 is the face opposite to the front end face 243 and the opposing face 244. The resin contact face 245 is the face in contact with the resin part 50 in the state after molding. The resin contact face 245 is two flat faces perpendicular to each other in the state before molding. However, the resin contact face 245 has a curved surface shape due to the deformation of the connecting part 24 in the state after molding. The resin contact face 245 corresponds to the resin side wall face.

[0035] Note that the connecting portion 24 may also be referred to as the first connecting portion with respect to the second connecting portion 34. Further, the connecting portion 24 may also be referred to as an arm portion or the like. In the present embodiment, an example in which the connecting portion 24 is provided on the first member 20 is adopted. However, the present disclosure is not limited to this. The connecting portion 24 may be provided on the bobbin.

[0036] As shown in FIG. 2, the base portion 25 is provided at the base of the connecting portion 24 on the flange portion 21 side. The base portion 25 is a portion for preventing the resin portion 50 from being formed at the base of the connecting portion 24. The base portion 25 corresponds to a rib.

[0037] The second member 30 has a flange portion 31, a cylindrical portion 32, a hole portion 33, a second connecting portion 34, and a base portion 35. The cylindrical portion 32 protrudes from the flange portion 31 in the axial direction. The flange portion 31 and the cylindrical portion 32 are provided with a hole portion 33 in which the core 40 is disposed. The flange portion 31 has the same outer shape as the flange portion 21.

[0038] The cylindrical portion 32 is provided continuously with the flange portion 31. The cylindrical portion 32 is provided with a fixing mechanism with the cylindrical portion 22. The cylindrical portion 32 corresponds to a cylindrical portion.

[0039] The second connecting portion 34 is provided at two adjacent corner portions of the flange portion 31. The second connecting portion 34 is a portion where the connecting portion 24 is connected (joined). As shown in FIG. 2, the base portion 35 is provided at the base of the second connecting portion 34 on the flange portion 31 side. The base portion 35 is a portion for preventing the resin portion 50 from being formed at the base of the second connecting portion 34. The base portion 35 corresponds to a rib.

[0040] The first member 20 and the second member 30 are integrated with the cylindrical portions 22 and 32 disposed in the hole portion 12. Further, the first member 20 and the second member 30 are integrated by being fixed by the fixing mechanism of the cylindrical portions 22 and 32. Note that, as a fixing mechanism, a method of fixing by fitting using an elastic force, such as a snap fit, can be adopted. However, the cylindrical portion 22 and the cylindrical portion 32 may be joined by other methods.

[0041] Also, the first member 20 and the second member 30 are positioned with respect to the coil 10 when the cylindrical portions 22 and 32 are disposed in the hole portion 12. The first member 20 and the second member 30 are positioned with respect to the core 40 when the core 40 is disposed in the hole portions 23 and 33. Therefore, the bobbin positions the coil 10 and the core 40 when the cylindrical portions 22 and 32 are disposed in the hole portion 12 of the coil 10 and the core is disposed in the hole portions 23 and 33.

[0042] Note that the flange portions 21 and 31 are arranged so as to sandwich the coil 10 in a state where the first member 20 and the second member 30 are integrated. That is, the flange portions 21 and 31 are disposed at both ends of the coil 10 in the axial direction.

[0043] In this embodiment, bobbins 20 and 30 having the divided first member 20 and second member 30 are adopted. However, the present disclosure can also be adopted for a bobbin in which the first member 20 and the second member 30 are integrally formed.

[0044] The core 40 is disposed in the hole portion 12. The core 40 is formed of a magnetic material and constitutes a magnetic circuit together with the coil 10. Magnetic flux generated by the current flowing through the coil 10 passes through the core 40. The core 40 is, for example, divided into a pair of U-shaped core parts, and an annular core is formed by opposing them.

[0045] As shown in FIGS. 1, 2, 3, etc., the resin part 50 has a base part 51, a mounting part 52, etc. The resin part 50 integrally covers the coil 10, the first member 20, the second member 30, and the core 40. The base part 51 is a part that covers the coil 10, etc. More specifically, the base part 51 does not cover the whole of the coil 10, the core 40, etc., but covers them in a state where a part is exposed.

[0046] The coil 10 generates heat when an electric current flows through itself. The heat generated from the coil 10 is transmitted to the core 40. Therefore, the base part 51 is provided in a state where a part of the coil 10 and the core 40 is exposed in order to dissipate the heat of the coil 10.

[0047] For this purpose, the base part 51 is provided with a first window part 53, a second window part 55, etc. The first window part 53 is a hole provided in the base part 51. The first window part 53 is provided in a facing area of a part of the upper wall 14. As a result, a part of the upper wall 14 is exposed from the base part 51 for the coil 10.

[0048] The second window part 55 is a hole provided in the base part 51. The second window part 55 is provided in a facing area of a part of the side wall 15. More specifically, the second window part 55 is provided so that a part of the core 40 facing the side wall 15 is exposed from the base part 51. However, the present disclosure can also adopt a configuration in which the first window part 53 and the second window part 55 are not provided.

[0049] Furthermore, as shown in FIG. 2, the resin part 50 is provided with the base part 51 in a state where at least a part of the bottom wall 13 is exposed. The base part 51 has an opening in the area surrounded by the flange parts 21, 31 and the pair of connecting parts 24. That is, the base part 51 is provided around the area surrounded by the flange parts 21, 31 and the pair of connecting parts 24. As a result, the reactor component 100 can enhance the heat dissipation from the bottom wall 13 compared to a configuration where the facing area of the bottom wall 13 is not open. The gap part 54 is the space between the connecting part 24 and the coil 10. The gap part 54 communicates with the opening of the base part 51.

[0050] In this embodiment, as shown in FIG. 2, an example is adopted in which a part of the core 40 is also exposed from the base 51 together with the bottom wall 13. However, the present disclosure is not limited to this.

[0051] Note that the attachment portion 52 is provided so as to protrude from the base 51. The attachment portion 52 is a portion for attaching the reactor component 100 to an object to be attached. The attachment portion 52 is provided with a through hole into which a fixing member such as a bolt is inserted. The reactor component 100 is attached to the object to be attached such that the bottom wall 13 faces the object to be attached. The reactor component 100 is fixed to the object to be attached by the attachment portion 52 with bolts or the like.

[0052] The reactor component 100 is preferably attached via a heat dissipation member such as a heat dissipation sheet or heat dissipation grease. As described above, the bottom wall 13 is exposed from the resin portion 50 of the reactor component 100. Therefore, the reactor component 100 can bring the bottom wall 13 into contact with the heat dissipation member. For this reason, the reactor component 100 can improve the heat dissipation performance as compared with a configuration in which the bottom wall 13 is not in contact with the heat dissipation member.

[0053] <Manufacturing method> The manufacturing method of the reactor component 100 will be described with reference to FIGS. 4 to 9. As shown in FIG. 4, the reactor component 100 is divided into a coil 10, a first member 20, a second member 30, and a core 40.

[0054] First, an assembling step of assembling the bobbin and the coil 10 is performed. In the assembling step, the cylindrical portions 22 and 32 are arranged in the hole portion 12 of the coil 10, and the first member 20 and the second member 30 are attached so that the coil 10 is sandwiched between both flange portions 21 and 31. Further, in the assembling step, as shown in FIGS. 5 and 9, a part of the coil 10 is sandwiched by the paired connecting portions 24, and the front end surface 243 is assembled so as to be in contact with the outer wall of the coil 10 from one open end to the other open end of the coil 10. Thereby, the bobbin and the coil 10 are assembled. The RCL in FIG. 9 is a resin cutting line. The resin cutting line is the boundary between the portion where the resin portion 50 is formed and the portion where it is not formed with respect to the coil 10.

[0055] Further, in the assembling step, the core 40 may be assembled to the bobbin and the coil 10. In this case, it is assembled so that a part of the core 40 is arranged in the hole portions 23 and 33. The assembled bobbin, coil 10, and core 40 correspond to a structure.

[0056] Next, an arranging step of arranging the structure in the mold 200 and a molding step of forming the resin portion 50 after the arranging step are performed. As shown in FIG. 6, in the arranging step, a part of the coil 10 sandwiched by the connecting portion 24 is arranged in a state of being separated from the periphery by the mold 200 and the connecting portion 24. That is, in the arranging step, the bottom wall 13 faces the mold 200, and the protruding portion 242 is arranged in contact with the mold 200. In the present embodiment, not only the connecting portion 24 but also the flange portions 21 and 31 are arranged in contact with the mold 200. Therefore, in the arranging step, the resin portion 50 is not formed in the space surrounded by the connecting portion 24, the flange portions 21 and 31, and the mold 200.

[0057] Then, as shown in FIG. 6, in the molding step, the resin portion 50 is formed so that a part of the coil 10 sandwiched by the connecting portion 24 is exposed from the resin portion 50. In the molding step, the resin portion 50 is formed by, for example, injection molding.

[0058] As shown by the white arrow in FIG. 6, in the molding process, a molding pressure is applied to the connecting portion 24. In the molding process, the connecting portion 24 is deflected from one open end of the coil 10 to the other open end by the molding pressure. At this time, the connecting portion 24 is deformed while the protruding portion 242 is in contact with the mold 200. Also, in the molding process, while pressing the coil side wall surface including the tip surface 243 against the outer wall of the coil 10 by the molding pressure, the resin portion 50 is formed. The outer wall here is the bent portion between the bottom wall 13 and the side wall 15 as described above.

[0059] In this way, in the molding process, the resin portion 50 is formed while pressing the connecting portion 24 against the outer wall of the coil 10. Therefore, the resin portion 50 is formed at the exposed portions of the upper wall 14 of the coil 10, the bent portion between the upper wall 14 and the side wall, and the connecting portion 24 of the side wall 15 with the resin cut line RCL as the boundary. Also, the resin portion 50 is not formed on the bottom wall 13 of the coil 10 and the bent portion between the bottom wall 13 and the side wall 15.

[0060] Note that the relationship between the molding pressure (pressure) applied to the connecting portion 24 and the amount of deflection of the connecting portion 24 can be analyzed by simulation or the like. The shape of the connecting portion 24 is designed based on the analysis result. That is, the connecting portion 24 is designed to have the above-described shape in the post-molding state.

[0061] <Effect> As described above, the reactor component 100 includes a bobbin having a connecting portion 24. The connecting portion 24 has a tip surface 243 and an opposing surface 244 in contact with the coil 10, and a resin contact surface 245 in contact with the resin portion 50, and partitions so that a part of the sandwiched coil 10 is exposed from the resin portion 50. Therefore, the reactor component 100 can prevent the resin portion 50 from being formed on a part of the coil 10 by the bobbin. For this reason, the reactor component 100 can prevent the resin portion 50 from being formed on a part of the coil 10 while suppressing an increase in the number of components.

[0062] Further, in the molded state, the resin contact surface 245 of the reactor component 100 has a curved surface shape. Therefore, the reactor component 100 can increase the contact area between the resin contact surface 245 and the base portion 51 compared to the configuration where the resin contact surface 245 is a flat surface.

[0063] The reactor component 100 is provided with a protruding portion 242 that protrudes from the end of the opposing portion 241. Therefore, the reactor component 100 can suppress a part of the resin portion 50 or foreign matter from entering the gap portion 54 in the molding process compared to the configuration where the protruding portion 242 is not provided. That is, the protruding portion 242 of the reactor component 100 deforms while contacting the mold 200. For this reason, it can be said that the protruding portion 242 has a function of suppressing a part of the resin portion 50 or foreign matter from entering the gap portion 54.

[0064] In addition, in the manufacturing method of the reactor component 100, in the molding process performed after the placement process, while bending the connecting portion 24 by the molding pressure and pressing the coil side wall surface including the tip surface 243 against the outer wall of the coil 10, the resin portion 50 is formed on the resin contact surface 245. Thereby, it is possible to manufacture the reactor component 100 in which the resin portion 50 is not formed on a part of the coil 10 while suppressing an increase in the number of parts of the reactor component 100.

[0065] In addition, since the manufacturing method of the reactor component 100 bends the connecting portion 24 and brings the tip surface 243 into contact with the coil 10, it can also absorb the tolerance of the connecting portion 24. That is, even if there is variation in the connecting portion 24, the resin portion 50 can be divided by the resin cut line RCL in the manufacturing method of the reactor component 100.

[0066] <Modification Example> The bobbin can also be adopted with a configuration as shown in the modified example of FIG. 10. The bobbin of the modified example includes a first member 20a having a pair of connecting portions 24a and a second member 30a having a pair of second connecting portions 34a. In a state where the first member 20a and the second member 30a are assembled, the first member 20a and the second connecting portion 34a are provided such that their tip portions contact each other. The first member 20a and the second connecting portion 34a have, for example, surfaces inclined with respect to the axis. Note that the connecting portion 24a and the second connecting portion 34a correspond to the connecting portion. That is, in the modified example, it can be said that the connecting portion 24a and the second connecting portion 34a are combined to form the connecting portion.

[0067] Although this disclosure has been described in accordance with the embodiments, it is understood that this disclosure is not limited to the embodiments or structures. This disclosure also includes various modified examples and modifications within an equivalent range. In addition, although various combinations and forms are shown in this disclosure, other combinations and forms that include only one element, more, or less than that are also within the scope and spirit of this disclosure.

[0068] (Disclosure of Technical Idea) This specification discloses a plurality of technical ideas described in a plurality of claims listed below. Some claims may be described in a multiple dependent form in which a preceding claim is alternatively cited in a subsequent claim. Further, some claims may be described in a multiple dependent form that refers to another multiple dependent form. The claims described in these multiple dependent forms define a plurality of technical ideas.

[0069] (Technical Idea 1) A cylindrical coil (10) wound and having openings at both ends, A core (40) disposed in the hollow portion of the coil, A positioning member for the coil and the core, including a cylindrical portion (22, 32) disposed in the hollow portion, two flange portions (21, 31) provided continuously to the cylindrical portion and disposed at both ends of the coil, and a pair of connecting portions (24, 24a, 34a) provided across the two flange portions, and a bobbin (20, 30). A resin portion (50) integrally covering the coil, the bobbin, and the core. The pair of connecting portions sandwich a part of the coil, and have a coil side wall surface (243, 244) including a portion in contact with the outer wall of the coil at at least a part between one opening end and the other opening end of the coil, and a resin side wall surface (245) which is the opposite surface of the coil side wall surface and in contact with the resin portion, and partition the resin portion so that a part of the sandwiched coil is exposed from the resin portion, a reactor component.

[0070] (Technical idea 2) The pair of connecting portions described in Technical idea 1, having an opposing portion that bends along the curved surface of the outer wall and the distance between them becomes narrower, and a protruding portion that is continuous with the opposing portion and the distance between them becomes wider.

[0071] (Technical idea 3) The pair of connecting portions described in Technical idea 1 or 2, where the distance between them gradually becomes narrower and then gradually becomes wider as going from one flange portion to the other flange portion.

[0072] (Technical idea 4) The opposing portion described in Technical idea 2 is thinner than the protruding portion, a reactor component.

[0073] (Technical idea 5) The height of the opposing portion described in Technical idea 2 or 4 is longer than the length of the protruding portion, a reactor component.

[0074] (Technical idea 6) The connecting part has a rib provided at the base with the flange part, and the reactor component according to any one of Technical Ideas 1 to 5.

[0075] (Technical Idea 7) The paired connecting parts are bent by the molding pressure when forming the resin part, and a part of the coil side wall surface is in contact with the outer wall, and the reactor component according to any one of Technical Ideas 1 to 6.

Explanation of Signs

[0076] 10…Coil, 11…Lead-out part, 12…Hollow part, 13…Bottom wall, 14…Side wall, 15…Upper wall, 20, 20a…First member, 21…Flange part, 22…Cylindrical part, 23…Hollow part, 24, 24a…Connecting part, 241…Opposing part, 242…Protruding part, 243…Tip surface, 244…Opposing surface, 245…Resin contact surface, 25…Claw part, 30, 30a…Second member, 31…Flange part, 32…Cylindrical part, 33…Hollow part, 34, 34a…Second connecting part, 35…Claw part, 40…Core, 50…Resin part, 51…Base part, 52…Mounting part, 53…First window part, 54…Void part, 55…Second window part, 100…Reactor component, 200…Mold, RCL…Resin cut line

Claims

1. A cylindrical coil (10) wound and having openings at both ends, a core (40) disposed in the hollow portion of the coil, a positioning member for the coil and the core, a cylindrical portion (22, 32) disposed in the hollow portion, two flange portions (21, 31) provided continuously with the cylindrical portion and disposed at both ends of the coil, and a pair of connecting portions (24, 24a, 34a) provided across the two flange portions, and a bobbin (20, 30) having the same; a resin portion (50) integrally covering the coil, the bobbin, and the core; The pair of connecting portions sandwich a part of the coil, and include a coil side wall surface (243, 244) that contacts the outer wall of the coil at at least a part between one opening end and the other opening end of the coil, and a resin side wall surface (245) that is opposite to the coil side wall surface and contacts the resin portion. The resin portion is partitioned so that a part of the sandwiched coil is exposed from the resin portion. The pair of connecting portions have an opposing portion that bends along the curved surface of the outer wall and has a reduced distance therebetween, and a protruding portion that is continuous with the opposing portion and has an increased distance therebetween. A reactor component.

2. The pair of connecting portions according to claim 1, wherein the distance between the pair of connecting portions gradually decreases and then gradually increases as it goes from one flange portion to the other flange portion.

3. The reactor component according to claim 1, wherein the opposing portion is thinner than the protruding portion.

4. The reactor component according to claim 1, wherein the height of the opposing portion is longer than the length of the protruding portion.

5. The reactor component according to claim 1, wherein the connecting portion is provided with ribs at the base with the flange portion.

6. The pair of connecting portions according to claim 1 or 2, which are bent by the molding pressure when forming the resin portion, and a part of the coil side wall surface is in contact with the outer wall.

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