Tamura Corporation

Tamura Fa System Corporation

Kensuke Maeno

Ryo Nakatsu

Kotaro Suzuki

Kaoru Hattori

Masashi Yamada

Masatoshi Hasu

Toshikazu Ninomiya

Sei Urano

Naoki Inoue

Tadayuki Okamoto

Ryotaro Tanaka

Koutarou Suzuki

Provided are a core and coil molding structure and a manufacturing method thereof which are capable of eliminating a void between coil layers to prevent foreign materials from entering therein, and which improve the vibration resistance and shock resistance of a reactor. A core and coil molding structure includes a coil that is a rectangular coil, a core yoke member in a block shape, and a resin member molding at least a part of those. The presence of a positioning member in a pin shape which positions the coil within a mold forms a groove in the inner circumference of the coil in the resin member.

Core and coil molding structure and manufacturing method thereof

A coil includes first and second coil elements both of which are formed by feeding one piece of a rectangular wire rod by a predetermined amount and winding rectangularly in an edgewise manner using winding heads, the first and second coil elements being wound in opposite directions from each other. A winding terminating end point of the first coil element is bent approximately 90 degrees in a direction opposite to a winding direction of the first coil element, and is connected to a winding terminating end point of the second coil element in a same flat plane. The second coil element includes an offset portion of the rectangular wire rod that is offset in a plan view from a side of the second coil element.

Coil and method for forming a coil

A reactor is provided which can be reduced in size, can prevent falling off of the temperature sensor and can make accurate temperature detection. The reactor comprises: an annular core; a resin membercovering a periphery of the annual core; a coilattached to an outer circumference of the resin member; and a temperature sensorinserted into a gap between the resin memberand the coil. The temperature sensorhas a columnar temperature detection portion, and at least a part of the temperature detection portionis sandwiched by the resin memberand the coilin close contact.

Reactor

A reactor coil includes first and second coil elements each formed by edgewise and rectangular winding of one piece of rectangular wire rod in a manner in which the wound rectangular wire rod is stacked rectangularly and cylindrically and, at a winding terminating end point of the first coil element, the rectangular wire rod is bent approximately 90 degrees in a direction opposite to the winding direction of the first coil element so that the rectangular wire rod is stacked in a direction opposite to the stacking direction of the first coil element and is wound edgewisely and rectangularly in a direction opposite to the winding direction of the first coil element to form the second coil element and, as a result, the first coil element and second coil element are aligned in parallel to each other in a continuous state.

A reactor includes a core, a resin cover provided around the core, and a coil disposed around the core at the external side of the resin cover. The coil includes a conductive wire having a self-fusing layer formed on the surface of the conductive wire, and the adjoining conductive wire portions are bonded together by the self-fusing layer. The resin cover includes a bonding portion provided at a part of the resin cover and facing the end portion of the coil, and the end portion of the coil are bonded with the resin cover by an adhesive at the bonding portion.

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.

Reactor and manufacturing method thereof

A resin-mold core includes right and left leg portions, and a yoke portion interconnecting those. The resin-mold core includes a magnetic core, and a mold component having the magnetic core embedded therein by molding. Openings where the magnetic core in the mold component is exposed are formed in multiple faces of the mold component that are upper, lower, front, rear, and right and left faces. A part of the yoke portion of the resin-mold core corresponding to a location where terminals are drawn to the exterior of the core from coils attached to the outer circumferences of the leg portions of the core has no opening formed in the multiple faces of the mold component. Positioning members to coaxially align the leg portions of the opposing resin-mold core are formed in abutting faces of the leg portions of the resin-mold core.

Resin-molded core and reactor using the same

A reactor includes an annular core, coils, a sensor detecting a state of the reactor, and a connector outputting signal from the sensor. Resin-molded bodies are provided around the annular core. The resin-molded body has bobbins for the respective coils and core covering portions formed integrally with each other. An exposed area where no resin covers the bottom of the core is formed in the lower face of the covering portions. A holder to fasten the connector is formed integrally with the upper portion of the covering portion. An assembly including the resin-molded bodies in which the annular core is embedded, and the coils wound around the bobbins are retained in a metal casing. A clearance is formed between the assembly and the casing, and a filler is filled in this clearance. The filler covers the exposed area of the core bottom.

Divided coresincludes left and right leg portions and a yoke portion and formed by molding a yoke portion side core material within resin. The leg portions of the divided core are formed by tubular core mounting portionsI-shaped leg portion side core materials-and spacersare mounted in the tubular core mounting portions. A ring-shaped molded coreis formed by abutting and integrating the respective leg portions of two divided cores, and a coilis wound around the molded core.

Method of manufacturing a reactor

A coil includes a coil unit provided with a wire and a self-melting layer formed on surfaces of the wire, and a resin member affixed to the wire. The wire is adhered and affixed to the resin member by the self-melting layer.

Coil and manufacturing method for same, and reactor

Resin-mold core and reactor using the same

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.

Divided coresincludes left and right leg portions and a yoke portion and formed by molding a yoke portion side core material within resin. The leg portions of the divided core are formed by tubular core mounting portions. I-shaped leg portion side core materials-and spacersare mounted in the tubular core mounting portions. A ring-shaped molded coreis formed by abutting and integrating the respective leg portions of two divided cores, and a coilis wound around the molded core.

Growing community of inventors

Saitama, Japan

Kensuke Maeno