reactor

Abstract

To provide a reactor that can suppress breakage of a holding part, and can improve productivity, and a method for manufacturing the reactor.SOLUTION: A reactor comprises: a pair of coils 5a, 5b which is arranged laterally while making winding shafts parallel; a holding part 7 which is provided between the pair of coils, and holds a sensor 6 while surrounding it in a U-shape; and a resin body 30(40) which covers a core member arranged outside the coils, where the holding part 7 is formed seamlessly and continuously with the resin body part covering the core member, and provided off an end face connected with the other core member of the core member in a winding shaft direction, and has: a pair of opposing parts 71, 72 which are arranged opposing to a direction parallel with the winding shaft direction, extend in a single direction so as to cross the winding shaft direction; and a connection part 73 connecting end parts of the pair of opposing parts. At least on one opposing part, a protrusion 74 protruding toward the other opposing parts 71, 72 is provided for an end part on the opposite side of the connection part, and the opposing parts 71, 72 and the connection part 73 are solid.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a reactor having a holder for holding a sensor, and a method for manufacturing the same. [Background technology]

[0002] Reactors are used in a variety of applications, including drive systems for hybrid and electric vehicles. For example, reactors used in in-vehicle boost circuits often have a pair of coils wound around a resin body that covers a core.

[0003] In this type of reactor, if a high current continues to flow through the coil, the coil will overheat and its electrical characteristics as a reactor will deteriorate. Therefore, the internal temperature is detected by a temperature sensor such as a thermistor, and current flow is controlled so that the coil does not heat up above a certain temperature. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-94924 Summary of the Invention [Problem to be solved by the invention]

[0005] As described above, the reactor is provided with a sensor for detecting a state, such as a temperature sensor, and a holder for holding the sensor. The holder is provided integrally with the resin body that covers the core.

[0006] FIG. 10 is a diagram showing the configuration of a conventional resin body and a holding part. FIG. 11 is a perspective view of the conventional holding part as seen from the top. FIG. 12 is a perspective view of the conventional holding part as seen from the bottom. As shown in FIG. 10, resin body 120 covers core members assembled to form an H shape and has two parallel long legs 121 and a connecting part 122 connecting the central parts of long legs 121. The coils constituting the reactor are fitted into, for example, four legs 123 bounded by connecting part 122. Holding part 107 is disposed between legs 123 and extends from connecting part 122 toward the tips of legs 123. However, holding part 107 does not protrude to the tips of legs 123.

[0007] As shown in Figure 11, the holding portion 107 has a pair of opposing portions 171, 172 extending in one direction, and a connecting portion 173 connecting the ends of the opposing portions 171, 172, and the opposing portion 172 has a protrusion 174 at the end opposite the connecting portion 173 that protrudes toward the opposing portion 171.

[0008] Conventionally, resin body 120 and holding portion 107 have been produced using a two-piece mold. Therefore, when providing protrusion 174 on facing portion 172, it is necessary to insert the convex portion of the mold for forming protrusion 174 into the facing portion 172 and connecting portion 173 to prevent protrusion 174 from forming an undercut in relation to connecting portion 173. As a result, resin is not filled in the portion where the convex portion has inserted, and therefore, as shown in FIGS. 11 and 12 , a hollow portion 175, which is a void, is formed in facing portion 172 and connecting portion 173, making facing portion 172 and connecting portion 173 thin. Therefore, when facing portion 172 is pushed open to widen the insertion opening when inserting a sensor, a load is applied to facing portion 172 or connecting portion 173, which can cause damage to these portions.

[0009] The present invention has been made to solve the above-mentioned problems, and its object is to provide a reactor and a manufacturing method thereof that can suppress damage to the holding portion and improve productivity. [Means for solving the problem]

[0010] The reactor of the present invention includes a pair of coils arranged side by side with their winding axes parallel to each other, a holding portion provided between the pair of coils and surrounding and holding the sensor in a U-shape, and a resin body covering a core member arranged outside the coils, wherein the holding portion is formed seamlessly as a continuation of the portion of the resin body covering the core member and is provided apart in the winding axis direction from an end face of one core member that is connected to another core member, and has a pair of opposing portions arranged opposite each other in a direction parallel to the winding axis direction and extending in one direction so as to intersect with the winding axis direction, and a connecting portion connecting end portions of the pair of opposing portions, wherein at least one of the opposing portions has a protrusion at an end opposite to the connecting portion that protrudes toward the other opposing portion, and the opposing portion and the connecting portion are solid. The protrusion is provided so as to overlap the connecting portion in the direction in which the pair of opposing portions extend, and a protruding portion is provided in the opposing portion farther from the end face, protruding in the winding axis direction from a surface opposite to a surface facing the other opposing portion, the protruding portion being provided below the protrusion and formed in the center so as to extend in the up-down direction. It is characterized by the fact that [Effects of the Invention]

[0012] According to the present invention, it is possible to obtain a reactor and a manufacturing method thereof that can suppress damage to the holding portion and improve productivity. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a perspective view of a reactor according to an embodiment. [Figure 2] FIG. 2 is an exploded perspective view of the reactor according to the embodiment. [Figure 3] FIG. 10 is a diagram showing the configuration of the holding portion, and is a side view of the resin body. [Figure 4] FIG. 10 is a diagram showing the configuration of the holding portion, and is a plan view of the resin body. [Figure 5] FIG. 10 is a perspective view of a resin body in which a sensor is held by a holding portion. [Figure 6] 10A and 10B are diagrams for explaining the method for manufacturing the reactor according to the embodiment, and are XZ cross-sectional views when molding a resin body having a holding portion. [Figure 7]10A and 10B are diagrams for explaining the method for manufacturing the reactor according to the embodiment, and are XY cross-sectional views when molding a resin body having a holding portion. [Figure 8] FIG. 2 is a perspective view of a resin body showing a parting line. [Figure 9] 10 is a diagram for explaining a manufacturing method according to another embodiment, and is an XZ cross-sectional view when molding a resin body having a holding portion. FIG. [Figure 10] 10A and 10B are diagrams showing the configuration of a conventional resin body and a holding portion. [Figure 11] FIG. 10 is a perspective view of a conventional holding portion as viewed from above. [Figure 12] FIG. 10 is a perspective view of a conventional holding portion as seen from the bottom side. DETAILED DESCRIPTION OF THE INVENTION

[0014] Hereinafter, a reactor according to an embodiment of the present invention will be described with reference to the drawings.

[0015] [1. Embodiment] [1-1. Outline configuration] Fig. 1 is a perspective view of a reactor according to an embodiment. As shown in Fig. 1, reactor 1 according to this embodiment has resin molded cores 2 to 4, coils 5a and 5b, and sensor 6. Two coils 5a and 5b are attached to the legs of H-shaped resin molded core 2, and sensor 6 is inserted between coils 5a and 5b. Sensor 6 is a temperature sensor in this example, and detects the temperature of reactor 1.

[0016] [1-2. Detailed configuration] The components of the reactor 1 will be described in detail. For ease of explanation, the direction in which the winding axes of the coils 5a and 5b extend (hereinafter simply referred to as the "winding axis direction") will be referred to as the X-axis direction, the direction in which the coils 5a and 5b are arranged side by side and perpendicular to the X-axis direction will be referred to as the Y-axis direction, and the direction perpendicular to the X-axis and Y-axis directions will be referred to as the Z-axis direction. The Y-axis direction will be referred to as the left-right direction, and the Z-axis direction will be referred to as the up-down direction. The direction indicated by the Y-axis arrow will be referred to as the right side, and the opposite side will be referred to as the left side, and the direction indicated by the Z-axis arrow will be referred to as the up side, and the opposite side will be referred to as the down side. These directions are used to indicate the positional relationships of the components of the reactor 1, and do not limit the positional relationships and directions when the reactor 1 is installed in an installation target.

[0017] 2 is an exploded perspective view of a reactor according to an embodiment. As shown in FIG. 2, resin molded core 2 has an H-shape and includes a core member and a resin body 20 that covers this core member. The core member covered by resin body 20 is formed by facing the legs of two T-shaped cores made of a magnetic material such as a powder magnetic core. Therefore, resin body 20 has an H-shape following the core member. In this way, the four legs of the H-shape constitute leg portions 21 of resin molded core 2.

[0018] The resin molded cores 3, 4 have a core member and a resin body 30, 40 that covers the core member. The core member covered by the resin body 30, 40 is a magnetic body such as a block-type powder magnetic core having a rectangular parallelepiped shape. Therefore, the resin body 30, 40 has a roughly rectangular parallelepiped shape in imitation of this core member. Further detailed configurations of the resin body 30, 40 will be described later.

[0019] The coils 5a, 5b are formed by winding a conducting wire and have a cylindrical shape. Here, the reactor 1 has two pairs of coils 5a, 5b. Each pair of coils 5a, 5b is attached to the legs 21 of the resin molded core 2 and is arranged side by side with its winding axes parallel. The spacing between the coils 5a, 5b is approximately the same as the thickness of the sensor 6. "Approximately the same as the thickness of the sensor 6" means that the sensor 6 can be inserted between the coils 5a, 5b without coming into contact with the coils 5a, 5b, and is less than twice the thickness of the sensor 6. One end of the coils 5a, 5b is electrically connected to each other, and the other end is drawn out above the reactor 1.

[0020] Reactor 1 is constructed by attaching coils 5a and 5b to leg portions 21 of resin molded core 2 and sandwiching leg portions 21 from their leading ends between resin molded cores 3 and 4. That is, by combining the core members of resin molded cores 2 to 4, an annular core having a roughly θ shape is formed. In reactor 1, when current flows from an external power source to coils 5a and 5b, coils 5a and 5b generate magnetic flux. This magnetic flux passes through the core members that make up the annular core, forming a closed magnetic circuit.

[0021] Resin bodies 30 and 40 cover core members disposed outside coils 5a and 5b. Openings are provided in resin bodies 30 and 40, and these openings expose end faces E that connect with end faces E of the core members exposed from resin body 20. These core members are block-shaped cores of resin molded cores 3 and 4.

[0022] Resin bodies 30 and 40 are provided with fixing portions 34 that fix reactor 1 to an installation target. Fixing portions 34 are provided with holes into which bolts are inserted, and here, are respectively arranged at the vertices of an isosceles triangle on reactor 1. Here, one fixing portion 34 is provided in the center of the top of resin body 30, and two fixing portions 34 are provided at both ends of resin body 40. Reactor 1 is housed in, for example, a metal case, and is fixed to the case by fastening bolts inserted into the holes in fixing portions 34.

[0023] As shown in FIG. 2 , the sensor 6 has a detection unit 61 and a lead wire 62. The detection unit 61 has a columnar shape, more specifically, a rectangular parallelepiped shape, and detects the temperature of the reactor 1. The detection unit 61 can be, for example, a thermistor whose electrical resistance changes with temperature. However, the detection unit 61 is not limited to a thermistor and may be a sensor such as a magnetic sensor, a current sensor, or a thermal fuse. The lead wire 62 is connected to the detection unit 61 and is a signal line that transmits an electrical signal output by the detection unit 61 to outside the reactor 1.

[0024] As shown in FIG. 2, reactor 1 includes a holding portion 7 that holds sensor 6. This holding portion 7 is provided between paired coils 5a, 5b, and surrounds and holds sensor 6 in a U-shape. The holding portion 7 is formed seamlessly and continuously with the portions of resin bodies 30, 40 that cover the core members, and is provided away in the winding axis direction (X-axis direction) from the end faces of the core members that are connected to other core members, i.e., the core members of resin molded core 2. In other words, the holding portion 7 is a part of resin bodies 30, 40.

[0025] 3 and 4 are diagrams showing the configuration of the holding portion 7, with Fig. 3 being a side view of the resin bodies 30 and 40 and Fig. 4 being a plan view of the resin bodies 30 and 40. Fig. 5 is a perspective view of the resin bodies 30 and 40 in which the sensor 6 is held by the holding portion 7.

[0026] The holding portion 7 is provided between the coils 5a and 5b. As shown in FIGS.

[0027] The pair of opposing portions 71, 72 are arranged facing each other in a direction parallel to the winding axis direction and extend in one direction intersecting the winding axis direction. Here, the pair of opposing portions 71, 72 extend in the vertical direction and are spaced apart in the winding axis direction by the thickness of detection portion 61 so that sensor 6 is inserted from above. Opposing portion 71 is arranged close to the core member, and opposing portion 72 is arranged far from the core member.

[0028] The connecting portion 73 connects the ends of the pair of opposing portions 71, 72. Here, the connecting portion 73 extends in the direction of the winding axis, and its length corresponds to the thickness of the detection portion 61. The pair of opposing portions 71, 72 and the connecting portion 73 form a U-shape that surrounds the sensor 6.

[0029] Specifically, in this embodiment, the holding portion 7 is configured as a slit extending in the vertical direction in a substantially rectangular plate-like body 70 that protrudes in the winding axis direction from the center of the portion of the resin bodies 30, 40 that covers the core member. The pair of opposing portions 71, 72 and the connecting portion 73 are edge portions of the plate-like body 70 that form the slit. The pair of opposing portions 71, 72 and the connecting portion 73 are solid. In other words, the pair of opposing portions 71, 72 and the connecting portion 73 are made of resin with no gaps between them.

[0030] In this way, the retaining portion 7 is configured as a slit in the plate-like body 70. In other words, the retaining portion 7 is formed seamlessly as a continuation of the resin bodies 30, 40 that cover the core member, and is provided away from the end face E of the core member in the winding axis direction. The end face E of the core member is the surface that is exposed from the resin bodies 30, 40 and is the surface that is connected to another core member. In this embodiment, the other core member is the T-shaped core of the resin molded core 2.

[0031] A pair of protrusions 74 are provided on the pair of opposing portions 71, 72. The pair of protrusions 74 are provided on the end portions of the opposing portions 71, 72 opposite the connecting portion 73. The protrusion 74 provided on the opposing portion 71 protrudes toward the opposing portion 72, and the protrusion 74 provided on the opposing portion 72 protrudes toward the opposing portion 71, narrowing the insertion opening of the holding portion 7 into which the sensor 6 is inserted. In other words, when the sensor 6 is inserted into the holding portion 7 from above and held therein, even if the sensor 6 tries to come out upward, the rear end of the detecting portion 61 abuts against the protrusions 74, preventing the sensor 6 from coming out.

[0032] The protrusions 74 are provided so as to overlap the connecting portion 73 in the extending direction of the pair of opposing portions 71, 72. Here, the pair of protrusions 74 and the connecting portion 73 overlap in the vertical direction.

[0033] The holding portion 7 is provided with a protruding portion 8. The protruding portion 8 is provided on the facing portion 72 that is far from the end face E of the core member. Specifically, the protruding portion 8 is provided on the opposite side of the facing portion 72 from the side facing the other facing portion 71. The protruding portion 8 is provided to protrude in the winding axis direction. In this example, the protruding portion 8 is a substantially rectangular plate-like body.

[0034] [1-3. Manufacturing method] A manufacturing method of the reactor 1 of this embodiment will be described with reference to Fig. 6 and Fig. 7. Fig. 6 is an XZ cross-sectional view when molding the resin body 40 having the holding portion 7. Fig. 7 is an XY cross-sectional view when molding the resin body 40 having the holding portion 7, and is a cross-sectional view of region R in Fig. 4 taken along line AA in Fig. 6. The manufacturing method of the reactor 1 includes a resin body molding step, a holding portion molding step, a protrusion molding step, and an assembly step.

[0035] The resin body molding step is a step of molding the resin bodies 20, 30, and 40 to form the resin mold cores 2 to 4. Specifically, in the resin body molding step, a core member is set in an upper mold and a lower mold that are divided in the vertical direction, and resin is filled to mold the resin bodies 20, 30, and 40.

[0036] The retaining portion molding process is a process of molding the retaining portion 7, and the retaining portion 7 is molded as part of the resin bodies 30, 40 during the resin body molding process. The protruding portion molding process is a process of molding the protruding portion 8. Here, the retaining portion molding process and the protruding portion molding process are performed together with the resin body molding process that molds the resin bodies 30, 40. In the resin body molding process, the retaining portion molding process, and the protruding portion molding process, the resin bodies 30, 40, the retaining portion 7, and the protruding portion 8 are molded using a mold that releases in at least two directions.

[0037] For example, when molding the resin body 40, as shown in Figure 6, the resin body 40 is molded using an upper mold 81 and a lower mold 82 that are divided into upper and lower halves and have an inner shape that imitates the resin body 40, and as shown in Figures 6 and 7, the retaining portion 7 and the protruding portion 8 are molded using a left mold 83 and a right mold 84 that are divided into left and right halves and have an inner shape that imitates the retaining portion 7 and the protruding portion 8.

[0038] That is, a block-shaped core member B is placed on the lower mold 82, and the core member B is fixed in place by using a jig to sandwich the end face E of the core member B and its opposite surface. A left mold 83 and a right mold 84 are set between the two end faces E, in front of the surface of the core member B where the end face E is located. The upper mold 81 is then placed over the lower mold 82 from above so that the upper end of the lower mold 82 abuts against the lower end of the upper mold 81, and the upper mold 81 and the lower mold 82 are combined. At this time, the mold formed by the combined upper mold 81 and lower mold 82 penetrates one side of the core member B in the left-right direction, and the left mold 83 and the right mold 84 enter the space formed by this penetration. This closes the space enclosed by the molds 81 to 84. The left and right molds 83 and 84 are spaced apart by the thickness, which is the left-right length of the plate-like body 70 and the protrusion 8.

[0039] When the space enclosed by the molds 81-84 is closed, the core member B is separated from the upper mold 81 and the lower mold 82 except for the portion in contact with the jig or the lower mold 82. Resin is then filled, for example, through a gate G provided on the upper mold 81. As shown by the arrows in FIG. 6 , this resin flows into the gaps between the upper and lower molds 81 and 82 and the core member B, and also flows into the gaps between the left and right molds 83 and 84 that mold the retaining portion 7 and the protruding portion 8. By filling the closed space within the molds 81-84 with resin and solidifying it, the resin body 40, the retaining portion 7 (the pair of opposing portions 71 and 72, the connecting portion 73, and the pair of protrusions 74), and the protruding portion 8 are molded integrally. That is, the portion of the resin body 40 that covers the core member B, the retaining portion 7, and the protruding portion 8 are seamlessly formed from the same resin. This forms the resin mold core 4. A rectangular tongue piece 41 (see FIG. 5) extending around the end face E in the XY plane and the XZ plane is formed by a mold (hereinafter referred to as a front mold) that slides in the X-axis direction.

[0040] 8, a parting line L is formed in the center of the plate-like body 70, the pair of opposing portions 71, 72, the connecting portion 73, the protrusion 74, and the protruding portion 8 that constitute the holding portion 7. This parting line L is a protrusion that is formed at the left and right boundary when the left and right molds 83, 84 are joined together.

[0041] The retaining portion molding process also includes an upper / lower mold release process and a left / right mold release process. That is, after the resin body 40, retaining portion 7, and protrusion 8 are molded, the front mold is released from the resin mold core 4. Then, the upper and lower molds 81, 82 are released from the resin mold core 4. For example, the upper mold 81 is released upward to open the top of the resin mold core 4, and the resin mold core 4 is pushed up and released from the lower mold 82 by a pin that penetrates the lower mold 82 from top to bottom. At this time, the left and right molds 83, 84 remain set on the resin mold core 4.

[0042] After the upper and lower molds 81 and 82 are released, the left and right molds 83 and 84 are released from the resin mold core 4 to remove the resin mold core 4. In the same manner as above, the resin body 30 is molded to produce the resin mold core 3.

[0043] Here, by providing the protrusion 8, the left and right molds 83, 84 are more easily released from the molds than in the conventional technology in which the protrusion 8 is not provided. In other words, by providing the protrusion 8, the amount of resin in contact with the left and right molds 83, 84 increases, and the overall resin mass consisting of the retaining portion 7 and the protrusion 8 becomes larger. The resin mass shrinks due to thermal contraction, that is, when the resin cools and solidifies. The larger the size of the resin mass, the greater the amount of shrinkage due to thermal contraction. Therefore, it is possible to reduce the sticking of the molded retaining portion 7 and the protrusion 8 to the left and right molds 83, 84.

[0044] The assembly process is a process in which the manufactured resin molded cores 2 to 4 are assembled with coils 5a and 5b to manufacture reactor 1. Specifically, coils 5a and 5b are fitted into two pairs of legs 21 of H-shaped resin molded core 2, and resin molded core 2 is sandwiched between resin molded cores 3 and 4 from both sides in the X-axis direction, and end faces of the core members exposed from each resin body 20, 30, and 40 are connected to manufacture reactor 1. Detecting units 61 are inserted from above between coils 5a and 5b of reactor 1, and are inserted into holding unit 7 to attach sensor 7 to reactor 1.

[0045] [1-4. Actions and Effects] (1) Reactor 1 of the present embodiment includes a pair of coils 5a, 5b arranged side by side with their winding axes parallel to each other; a retaining portion 7 that is provided between the pair of coils 5a, 5b and surrounds and holds sensor 6 in a U-shape; and a resin body 30 (40) that covers a core member that is arranged on the outside of coils 5a, 5b. Retaining portion 7 is formed seamlessly as a continuation of the portion of resin body 30 (40) that covers the core member and is provided away in the winding axis direction from end face E of one core member that connects to another core member. Reactor 1 has a pair of opposing portions 71, 72 that are arranged facing each other in a direction parallel to the winding axis direction and extend in one direction so as to intersect with the winding axis direction, and a connecting portion 73 that connects the ends of the pair of opposing portions 71, 72. At least one of opposing portions 71, 72 has a protrusion 74 at an end opposite to connecting portion 73 that protrudes toward the other opposing portion 71, 72. This makes opposing portions 71, 72 and connecting portion 73 solid. This improves the strength of the holding portion 7 and improves productivity.

[0046] (2) A pair of protrusions 74 are provided on the pair of opposing portions 71, 72. This prevents the sensor 6 from falling out. That is, in conventional reactors, the resin mold core is produced using upper and lower molds, so the shape of the holding portion 107 needs to be such that there are no undercuts in the vertical direction. In the conventional holding portion 107, in order to prevent the sensor 6 from falling out, protrusions 174 are provided on the opposing portions 171, 172, so that even if the sensor 6 tries to fall out, the rear end of the sensor 6 abuts against the protrusions 174, preventing the sensor 6 from falling out.

[0047] This protrusion 174 is formed so as not to overlap in the vertical direction with the connecting portion 173. In other words, the portion of the connecting portion 173 where the protrusion 174 overlaps in the vertical direction must be hollow, and considering the strength of the facing portions 171 and 172, the protrusion 174 is provided only on one of the facing portions 172, which poses a problem that the sensor 6 is easily dislodged.

[0048] In contrast, in this embodiment, the holding portion 7 is formed by a method using not only molds 81 and 82 that release from the top and bottom, but also molds 83 and 84 that release from the left and right, so there is no need to worry about the vertical overlap of the protrusions 74 and the connecting portion 73. This increases the degree of freedom in the shape of the holding portion 7. In this embodiment, the protrusions 74 are provided on both opposing portions 71 and 72, so it is possible to further prevent the sensor 6 from falling out.

[0049] (3) The pair of protrusions 74 are provided so as to overlap the connecting portion 73 in the direction in which the pair of facing portions 71, 72 extend. This makes it possible to regulate the position of the sensor 6 in the direction in which the facing portions 71, 72 extend.

[0050] (4) The facing portions 71, 72 farthest from the end face E of the core member are provided with protruding portions 8 protruding in the winding axis direction on the side opposite the side facing the other facing portions 71, 72. This increases the overall resin mass of the holding portion 7 and the protruding portions 8, thereby increasing the amount of shrinkage due to thermal contraction. As a result, the holding portion 7 (particularly the facing portions 72 and the connecting portion 73) can be reduced from sticking to the left and right molds 83, 84, making it easier to release the left and right molds 83, 84. This prevents damage to the holding portion 7 when the left and right molds 83, 84 are released, improving productivity. Furthermore, when inserting the sensor 6 into the holding portion 7, the protruding portions 8 can be pinched to widen the insertion opening, thereby facilitating insertion of the sensor 6, improving worker production efficiency.

[0051] (5) A method for manufacturing a reactor 1 according to the present embodiment is a method for manufacturing a reactor 1 having a pair of coils 5a, 5b arranged side by side with their winding axes parallel, a holding portion 7 provided between the pair of coils 5a, 5b and surrounding and holding a sensor 6 in a U-shape, and a resin body 30 (40) covering a core member arranged outside the coils 5a, 5b, in which the holding portion 7 is provided away in the winding axis direction from an end face of a core member that is connected to another core member, and is arranged opposite in a direction parallel to the winding axis direction and is arranged so as to intersect with the winding axis direction. The method includes a resin body molding step in which the core member is set in upper mold 81 and lower mold 82 which are divided into upper and lower halves perpendicular to the direction of the reel and the direction of horizontal alignment, and resin is filled in to mold the resin body 30 (40); and a retaining part molding step in which, during the resin body molding step, the retaining part 7 is molded as part of the resin body 30 (40) using left mold 83 and right mold 84 which are divided into left and right halves in the direction of horizontal alignment.

[0052] This allows the pair of opposing portions 71, 72 and the connecting portion 73 to be solid, making it possible to obtain a reactor 1 that can suppress damage to the holding portion 7, and as a result, productivity can be improved.

[0053] (6) A protrusion molding process is provided in which the left mold 83 and the right mold 84 are used to mold the protrusion 8 protruding in the winding axis direction on the side of the opposing portions 71, 72 farther from the end face, opposite the side opposing the other opposing portions 71, 72.

[0054] This prevents damage to the retaining portion 7 and improves productivity. Specifically, if the protrusion 8 is not provided, when the left and right molds 83 and 84 are demolded, the retaining portion 7 may be small as a lump of resin and may stick to either the left mold 83 or the right mold 84, making it difficult to separate. In this case, forcing the molds to be demolded may place a load on the retaining portion 7, such as the connecting portion 73, which may result in damage to the retaining portion 7. In contrast, in this embodiment, the protrusion 8 is provided in the protrusion molding process. This increases the overall size of the retaining portion 7 and the protrusion 8, thereby increasing the amount of shrinkage that occurs when the resin cools, thereby reducing adhesion between the left and right molds 83 and 84. This facilitates demolding of the left and right molds 83 and 84 and prevents damage to the retaining portion 7. As a result, productivity can be improved.

[0055] 2. Other Embodiments The present invention is not limited to the embodiments, but also includes other embodiments described below. The present invention also includes a combination of all or any of the embodiments and the other embodiments described below. Furthermore, various omissions, substitutions, and modifications can be made to these embodiments without departing from the scope of the invention, and such modifications are also included in the present invention.

[0056] (1) In the above embodiment, the resin bodies 30 and 40 cover a block-shaped core member, but they may also cover a U-shaped core as the core member. The tip surfaces of the legs of the U-shape are exposed from the resin bodies 30 and 40 and serve as end surfaces that connect to other core members. The holding portion 7 is located further away from these end surfaces in the winding axis direction. This is because the holding portion 7 is molded using a mold that is divided into left and right halves.

[0057] (2) In the above embodiment, the protrusion 8 is molded using left and right molds 83 and 84. However, it may also be molded using separate left and right molds separated into left and right halves. In this case, a parting line L is formed in the protrusion 8 in the vertical direction. Furthermore, the left and right molds 83 and 84 may be configured as a sliding mechanism that moves in conjunction with the upper mold 81 and the lower mold 82 and slides a pair of left and right metal blocks that mold the retaining portion 7 and the protrusion 8 in the horizontal direction. The metal blocks may move horizontally together with the movement of the upper mold 81 and the lower mold 82, or may move after the movement of the upper mold 81 and the lower mold 82.

[0058] 9, molding may be performed using upper and lower molds 81 and 82. In this case, a parting line L that divides the protrusion 8 into upper and lower halves is formed. However, according to the above embodiment, since both the resin bodies 30 and 40 and the protrusion 8 can be molded using the upper and lower molds 81 and 82, the number of molds can be reduced, thereby reducing production costs. Molding may also be performed using a mold that is separated into upper and lower halves and is independent of the upper and lower molds 81 and 82. In this case, a parting line L that divides the protrusion 8 into upper and lower halves is formed.

[0059] (3) In the above embodiment, the pair of opposing portions 71, 72 extend in the vertical direction perpendicular to the winding axis direction and the lateral arrangement direction. However, they may be arranged so as to intersect with the winding axis direction. In this case, the detecting portion 61 of the sensor 6 is held by the holding portion 7 in a state inclined with respect to the vertical direction. Therefore, even if the length of the detecting portion 61 is long, the height of the reactor 1 can be made lower than in an embodiment in which the detecting portion 61 is held parallel to the vertical direction. [Explanation of symbols]

[0060] 1 reactor 2~4 resin mold core 20 Resin body 21 Legs 30 Resin body 34 Fixed part 40 Resin body 41 Tongue piece 5a, 5b coils 6 sensors 61 Detector 62 Lead wire 7 Holding part 70 Plate-shaped body 71, 72 opposing parts 73 Connecting part 74 Protrusion 8 Protrusion 81 Upper mold 82 Lower mold 83 Left-hand type 84 Right-hand type E End face

Claims

1. A pair of coils arranged side by side with their winding axes parallel to each other; a holding portion provided between the pair of coils and surrounding and holding the sensor in a U-shape; a resin body that covers a core member that is disposed on the outside of the coil; Equipped with the holding portion is formed seamlessly and continuously with the resin body that covers the core member, and is provided spaced apart in the winding axis direction from an end face of the core member that is connected to another core member, a pair of opposing portions disposed opposite to each other in a direction parallel to the winding axis direction and extending in one direction so as to intersect with the winding axis direction; a connecting portion connecting the ends of the pair of opposing portions; and At least one of the opposing portions is provided with a protrusion at an end opposite to the connecting portion, the protrusion protruding toward the other opposing portion, the opposing portion and the connecting portion are solid, the protrusion is provided to overlap the connecting portion in the extending direction of the pair of opposing portions, a protruding portion is provided in the opposing portion farther from the end face, the protruding portion protruding in the winding axis direction from a surface thereof opposite to a surface thereof facing the other opposing portion, the protruding portion is provided below the projection and is formed in the center so as to extend in the up-down direction; A reactor characterized by the above.

2. the protrusions are provided on the pair of opposing portions; The reactor according to claim 1,

3. The core member has a rectangular parallelepiped shape or a U-shape; The reactor according to claim 1 or 2,

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