Reactor and manufacturing method thereof

Abstract

First and second divisional cores each including right and left leg portions and a yoke interconnecting those together are formed by molding respective yoke-side core members in a resin. Cylindrical core mounting portions extending from the outer circumference of the surface of the yoke-side core member are formed integrally with the respective right and left leg portions of the first divisional core. I-shaped leg-portion-side core members and spacers are attached in the cylindrical core mounting portion formed in each of the right and left leg portions. The surface of the yoke-side core member molded in the resin and the surface of the leg-portion-side core member are disposed so as to have a spacer therebetween. The two divisional cores are joined together by butting respective leg portions of the two divisional cores with each other to form an annular mold core, and a coil is wound around the mold core.

Claims

1. A reactor comprising: an annular core including a first divisional core and a second divisional core that is connected to the first divisional core, the first divisional core is formed by a U-shaped first resin mold body which covers a portion of a first yoke-side core member and protrudes to form right and left hollow leg portions extending outward from the first yoke-side core member into which right and left leg-portion-side core members are inserted into right and left hollow leg portions, and the second divisional core is formed by a U-shaped second resin mold body which covers a second yoke-side core member and has an opening which will partially expose a back surface of the second yoke-side core member.

2. The reactor according to claim 1, wherein the right and left hollow leg portions and the second resin mold body have latch members for regulating a position between the first and second divisional core.

3. The reactor according to claim 2, wherein the right and left hollow leg portions have a protruding tongue piece and the second resin mold body has a complementary recess to receive the protruding tongue piece.

4. The reactor according to claim 2, wherein the second resin mold body has a protruding tongue piece and the right and left hollow leg portions have a complementary recess to receive the protruding tongue piece.

5. The reactor according to claim 1, further comprising a coil wound around the annular core and a casing with an open top retaining therein the annular core and the coil.

6. The reactor according to claim 1, wherein the opening is a slit that extends in a lateral direction of the back surface.

7. A reactor comprising: an annular core including a first divisional core and a second divisional core that is connected to the first divisional core, the first divisional core is formed by a U-shaped first resin mold body which covers a portion of a first yoke-side core member and protrudes to form right and left hollow leg portions extending outward from the first yoke-side core member into which right and left leg-portion-side core members are inserted into right and left hollow leg portions, and the second divisional core is formed by a U-shaped second resin mold body which covers a second yoke-side core member while leaving end faces of the second yoke-side core member exposed within resin hollow right and left leg portions of the U-shaped second resin mold body that protrude from the second yoke-side member each of a configuration to accommodate the insertion of the right and left hollow leg portions of the first divisional core to abut adjacent the respective end faces of the second yoke-side core member.

8. The reactor according to claim 7 wherein the first yoke-side core member and the second yoke-side core members have the U-shaped cores with end faces positioned within the respective right and left hollow resin leg portions to contact the right and left leg-portion-side core members when inserted.

9. The reactor according to claim 7, wherein the right and left hollow leg portions are integral extensions of the second resin mold body and the second resin mold body have latch members for regulating a position between the first and second divisional core.

10. The reactor according to claim 8, wherein the right and left hollow leg portions have a protruding tongue piece and the second resin mold body has a complementary recess to receive the protruding tongue piece.

11. A reactor comprising: an annular core including a first divisional core and a second divisional core; a first yoke-side core member and a second yoke-side core member; the first divisional core is provided with a right and a left hollow leg-portion-side core members formed by a first resin mold body that is formed on and encloses a substantial portion of the first yoke side core member while leaving a surface of the first yoke-side core member exposed within each of the right and left hollow leg portion-side core members that extend outward from the first yoke-side core member; the second divisional core is provided with a right and a left hollow leg-portion-side core members formed by a second resin mold body that is formed on and encloses a substantial portion of the second yoke side core member while leaving a surface of the second yoke-side core body exposed within each of the right and left hollow leg-portion-side core members that extend outward from the second yoke-side core member; leg-portion-side core members and spacers are mounted within the right and left hollow leg-portions of the first divisional core and the second divisional core; a first coil is mounted on the respective right and left leg-portions of the first divisional core and a second coil is mounted on the respective right and left leg-portions of the second divisional core; and a casing having an open top and a closed bottom with a bottom surface configured to receive and support the first and second-yoke side core members and the first and second coils.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view illustrating a reactor according to an embodiment of the present invention in an assembled condition;

(2) FIG. 2 is an exploded perspective view illustrating the reactor illustrated in FIG. 1; and

(3) FIG. 3 is a cross-sectional view illustrating a manufacturing method of the reactor illustrated in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

1. Structure of Embodiment

(4) As illustrated in FIGS. 1 and 2, a reactor according to an embodiment includes a mold core 1, a coil 100 wound around this mold core 1, and a casing 101 retaining there inside the mold core 1 and the coil 100. The mold core 1 has a first divisional core 11 and a second divisional core 12 integrated together in a manner abutting against each other and in an annular shape.

(5) The first divisional core 11 includes right and left leg portions 11a and 11b, and a yoke 11c interconnecting those leg portions. As illustrated in FIG. 3, the first divisional core 11 is formed by molding a U-shaped first yoke-side core member 21 in a resin 3. Respective surfaces 21a of the right and left ends of the yoke-side core member 21 molded in the resin 3 are exposed at the right and left leg portions 11a and 11b of the first divisional core 11.

(6) The right and left leg portions 11a and 11b of the first divisional core 11 are provided with cylindrical core mounting portions 4a and 4b extending from the outer circumference of an end surface of the yoke-side core member 21. The core mounting portions 4a and 4b are formed together by the resin 3 molded on the outer circumference of the yoke-side core member 21. Leg-portion-side core members 51, 52, and 53 each in an I-shape are fitted in the cylindrical core mounting portions 4a and 4b with a spacer 6 held between the respective core members. The surface 21a of the end portion of the first yoke-side core member 21 molded in the resin 3 and the surface of the leg-portion-side core member 51 are disposed so as to have the spacer 6 therebetween.

(7) The second divisional core 12 includes right and left leg portions 12a and 12b, and a yoke 12c interconnecting those leg portions together with an opening 12d. As illustrated in FIG. 3, the U-shaped second divisional core 12 is formed by having a second yoke-side core member 22 molded in the resin 3. Surfaces 22a of the right and left ends of the second yoke-side core member 22 molded in the resin 3 are exposed at the respective ends of the right and left leg portions 12a and 12b of the second divisional core 12.

(8) Latch members are provided at the respective tips of the leg portions 11a and 11b of the first divisional core 11. The latch members regulate the position between the first divisional core 11 and the second divisional core 12 when both are abut with each other. Specifically, recesses 8 are provided in the upper face and the lower face of each core mounting portion 4a and 4b of the first divisional core 11. Protruding tongue pieces 7 are provided on the upper face and the lower face of each leg portion 12a and 12b of the second divisional core 12. Protruding tongue pieces 7 are inserted into the respective recesses 8, thereby positioning the first divisional core 11 and the second divisional core 12.

(9) Fasteners 9 are integrally provided at the yokes 11c and 12c of the first and second divisional cores 11 and 12. Those fasteners 9 fasten the mold core 1, around which the coil 100 is wound, to the casing 101. Each base portion of the fasteners 9 is molded in the resin 3, which configures the first and second divisional cores 11 and 12, together with the yoke-side core members 21 and 22, respectively. The fastener 9 is provided with a bolt hole 10. A separately prepared bolt is inserted in the bolt hole 10, and the tip of this bolt is screwed in an unillustrated threaded hole provided in the casing 101, thereby fastening the mold core 1 to the casing 101.

2. Action of Embodiment

(10) The reactor of the embodiment employs the above-explained structure, and a method of manufacturing this reactor is as follow. (1) The U-shaped first yoke-side core member 21 and the fastener 9 are set in a die for forming the right and left leg portions 11a and 11b, the yoke 11c interconnecting those together, and the cylindrical core mounting portions 4a and 4b. The resin 3 is filled in the die and cured. The first divisional core 11 thus manufactured is taken out from the die. (2) The U-shaped second yoke-side core member 22 and the fasteners 9 are set in a die for forming the right and left leg portions 12a and 12b, and the yoke 12c interconnecting those together. The resin 3 is filled in the die and cured. The second divisional core 12 thus manufactured is taken out 30 from the die. (3) The spacers 6 and the I-shaped leg-portion-side core members 51 to 53 are inserted into each core mounting portion 4a and 4b of the manufactured first divisional core 11. In this case, each core member and spacer may be joined by a bond, or simply the spacers 6 and the leg-portion-side core members 51 to 53 may be fitted into the core mounting portion 4a or 4b. (4) The two core mounting portions 4a and 4b of the first divisional core 11 mounted with the core members and the spacers are respectively inserted through the coils 100, thereby mounting the coils 100 to the leg portions of the core. (5) The respective ends of the core mounting portions 4a and 4b of the first divisional core 11 and the respective ends of the leg portions 12a and 12b of the second divisional core 12 are butted against each other in such a way that the spacers 6 fitted in the respective core mounting portions contact the respective surfaces 22a of the ends of the second yoke-side core member 22, thereby forming the annular mold core 1. In this case, the tongue pieces 7 of the second divisional core 12 are fitted into the recesses 8 of the first divisional core 1, thereby positioning the two divisional cores 11 and 12. (6) The annular mold core 1 mounted with the coils 100 is retained in the casing 101, and the mold core 1 and the casing 101 are fastened together using unillustrated bolts and the fasteners 9.

3. Advantage of Embodiment

(11) The reactor and the manufacturing method thereof according to the embodiment have following advantages. (1) In this embodiment, only two core members, that are the yoke-side core members 21 and 22, are molded in the resin 3. Therefore, positioning of the core members in a die can be carried out easily and precisely in comparison with the conventional technology molding multiple core members simultaneously. (2) The leg-portion-side core members 51 to 53 and the spacers 6 are guided by each cylindrical core mounting portion 4a and 4b formed of the resin 3 of the first divisional core 11, and positioned relative to the first yoke-side core member 8 molded in the resin 3. Accordingly, each core member and spacer can be precisely positioned. (3) The leg-portions-side core members 51 to 53 and the spacers 6 are fitted into each cylindrical core mounting portion 4a and 4b formed of the resin 3 of the first divisional core 11. Therefore, it is not necessary to mount the leg-portion-side core members and the spacers into the second divisional core 12. Hence, the mounting of the leg-portion-side core members and the spacers and the joining of the two cores can be made simply in comparison with a case in which the leg-portion-side core members and the spacers are mounted into both divisional cores and then both divisional cores are joined together. (4) The leg-portion-side core members and the spacers are held from the entire surroundings by each cylindrical core mounting portion 4a and 4b formed of the resin 3. Accordingly, each core member and spacer can ensure a contacting condition without a bond, and thus the assembling work is simplified. It is needless to say that a bond can be used. (5) The leg-portion-side core members and the spacers are covered by each cylindrical core mounting portion 4a and 4b formed of the resin 3. Accordingly, the coil 100 and the core members are surely insulated from each other. (6) The two divisional cores 11 and 12 are fixed by fastening the fasteners 9 at both ends to the casing 101 by means of bolts. Accordingly, another member for maintaining the joined condition of both divisional cores is unnecessary at the joined portion of the divisional cores. In particular, it is unnecessary to provide an engagement member at the joined portion, fix the joined portion by adding a resin therearound, or use a coil bobbin so as to prevent a separation of the two cores. This simplifies the structure of the reactor.

4. Other Embodiments

(12) The present invention is not limited to the above-explained embodiment, and covers the following other embodiments. (1) The number of leg-portion-side core members and that of spacers mounted inside of each cylindrical core mounting portion 4a and 4b are not limited to the illustrated numbers, and may be larger or smaller numbers. Moreover, individual leg-portion-side core member and spacer may have different dimension in the axial direction of the leg portion (i.e., thickness) between the right and left core mounting portions 4a and 4b. The core members and the spacers having a different dimension may be used even in the same core mounting portion 4a and 4b. (2) The first yoke-side core member 21 and the second yoke-side core member 22 may be in an I-shape instead of the U-shape. In this case, exposed portions facing with the leg portion of the annular core are provided at the right and left side surfaces of each I-shaped yoke-side core members 21 and 22. The I-shaped cores for the leg portions are disposed so as to face the exposed portions with the spacers 6 therebetween. (3) The work of attaching the leg-portion-side core members and the spacers to the first divisional core 11 and the work of attaching the coil can be carried out in any sequence. (4) Other means for fastening the two butted divisional cores 11 and 12 together may be employed in addition to the fastening the fasteners provided at the mold cores to the casing by bolts. For example, the two divisional cores 11 and 12 may be fastened by a belt-shaped fastener wrapped around the divisional cores, or the whole annular mold core and coil may be further molded by the resin. (5) The latch members for positioning the two divisional cores may be provided at portions other than the mounting portions of the divisional cores 11 and 12. Moreover, other than the above-explained tongue pieces 7 and recesses 8 simply positioning the divisional cores, engagement members, such as a recess and a hook engaged with the recess can be employed to suppress a separation of the combined two divisional cores. The core mounting portions of the one divided core may be provided with a tongue piece and a recess, and another core mounting portions may be provided with a recess and a tongue piece respectively corresponding to the former tongue piece and recess. Furthermore, a cylindrical member may be provided which enables the tip of the one core mounting portion to be fitted in the tip of another core mounting portion. The portion where the latch member is provided is not limited to the core mounting portion, and the latch member can be provided at another portion of the leg portion.