Tamura Corporation

Kotaro Suzuki

Ryo Nakatsu

Kensuke Maeno

Tsutomu Hamada

Naoki Inoue

Toshikazu Ninomiya

Yasuhiro Uekusa

Kosuke Shibasaki

A reactor that suppresses the transmission of the vibration of the core and the vibration of the coil and that reduces the vibration thereof is provided. The reactor includes a coilwith a cylindrical shape and a corehaving legsaround which the coilis wound. The core includes a core mold resinwhich covers at least a part of the core, and a core holder which holds the core. The coilincludes a coil mold resinwhich covers at least a part of the coil, and a coil holder which holds the coil. The core holder and the coil holder independently hold the coreand the coil, respectively, and a gap Sis provided between the legsand the inner circumferential surface of the coil

Reactor

A reactor capable of suppressing a deformation of a resin material in a gap between partial cores is provided. This reactor includes: a core that includes T-shaped cores which are at least a pair of partial cores disposed via the gap therebetween; a coil attached to respective parts of the T-shaped cores; and a core casing that is a core molding member which is formed integrally by a resin material and which covers the T-shaped cores. The core casing includes the coupling portion that is provided between the T-shaped cores at a location corresponding to the gap, and the coupling portion is provided with a through-hole, and a pair of connection portions which face with each other across the through-hole and which connects a space between the T-shaped cores.

A small size reactor that effectively utilizes a space is provided. This reactor includes: a reactor body which includes a core and a coil attached to the core, a casing which houses therein the reactor body and which has an opening where a part of the reactor body protrudes outwardly, a bus bar which is a conductive component electrically connected to the coil and which covers a part of a side of the reactor body protruding from the opening, and a terminal stage which includes an extended portion formed of a resin material where a part of the bus bar is embedded and provided along an edge of the opening, and which supports an electrical connection portion between the bus bar and an exterior.

A reactor includes: a reactor body having a core; and an installation destination object on which the reactor body is mounted; wherein the reactor body has three fixing portions for fixing the reactor body to the installation destination object, the installation destination object has mount portions for mounting the fixing portions, and the reactor body is fixed to the installation destination object by the fixing portions being mounted on the mount portions.

An annular core includes an upper core and a lower core. A coil is attached to the leg of the annular core in a way that the winding axis is aligned in the vertical direction. The surface of the upper core is covered by an upper cover formed of resin. The surface of the lower core is covered by the lower cover formed of resin. A casing formed of metal includes a bottom plate having an opening, and a side wall integrated with the bottom plate, and the lower core, the coil, and the upper core are housed in the casing. A part of the lower cover is exposed via the opening of the casing. A filler resin is filled in a gap between the circumference of the annular core and the coil, and the side wall of the casing or the lower cover.

Reactor and method of manufacturing thereof

A method of manufacturing a reactor includes a pair of coils and a pair of core units of partial I-shaped cores with gap members butted together and mounted in the coils. The respective ends of the I-shaped cores are pressed against the ends of a pair of U-shaped cores. The U-shaped cores and the I-shaped cores are formed by pressing powder in movable dies that preheat any burrs formed during pressing to be positioned in a direction different from the winding axis direction to avoid any contact with the coil.

Reactor manufacturing method

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 reactor includes a core made of a magnetic material; a resin mold that encloses the core; a coil that is wound around the core through the resin mold; a plurality of fasteners located on the resin mold; and a supporting member that is secured to the resin mold through the fasteners. At least one of the plurality of fasteners is a flexible fastener.

Reactors

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

U-shaped cores and fasteners are embedded in resin members, and brackets provided at respective ends of the fasteners protrude from the resin members. By fixing the brackets and a casing with screws, a reactor main body and the casing are fixed together. Openings formed by a partition wall that suppresses a direct application of a resin flowing from resin-filling portions to the fasteners are provided between the respective fasteners and the respective resin-filling portions. A protrusion extending in an opposite direction to a core and in parallel with the partition wall is provided between the resin-filling portions and the partition wall. The resin flowing from the resin-filling portion flows in between a core upper face and the fastener, and between a fastener surface located behind the partition wall and the internal surface of a die.

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Sakado, Japan

Kotaro Suzuki