Toyota Jidosha Kabushiki Kaisha

Tokai Kogyo Company Limited

Kabushiki Kaisha Toyota Jidoshokki

Nobuki Shinohara

Takeshi Okada

Shuichi Hirata

Kazuo Hirasawa

Yoshikazu Kamikawa

Akio Kitami

Shinjiro Saigusa

Takashi Atsumi

Masaki Sugiyama

Shuji Yokota

Mao Nobusaka

A reactordisclosed by the present specification is equipped with two coilsthat are arranged parallel to each other, a resin coverthat adheres to the two coils to cover the coils, and a column member. The resin coverexposes lateral faces of the coils on such a side as to be in contact with a common tangential plane KL. The column memberis arranged parallel to the coilsin a space that is surrounded by the common tangential plane KL and the lateral faces of the respective coils. The column memberis exposed on a side thereof that is opposed to the common tangential plane KL, and is in contact with the respective coilson the other side thereof. Furthermore, the column memberhas a groovethat has an opening on the other side of the common tangential plane KL and extends along coil axes. The groove has a width that is narrow at the opening and widens toward a bottom of the groove. An interior of the groove is filled with resin of the resin cover

Reactor

A manufacturing method of a reactor includes: assembling an assembly constituted by a coil and a bobbin by inserting the bobbin, which includes a tube portion and a flange portion, through the coil so that a tip of the tube portion protrudes from the coil; forming a cavity by installing the assembly in a first die so that a portion of a coil lateral face comes into contact with a cavity face of the first die, and closing a second die so that the second die is opposed to the first die; and extending first press rods from a cavity face of the second die toward the bobbin in the cavity, and injecting a resin into the cavity while pressing both ends of the bobbin in an axial direction of the coil from an opposite side to the portion of the coil lateral face.

Manufacturing method of a reactor

A reactor includes: a bobbin including flanges at ends of a winding range of a winding, at least one of the flanges being provided with a slit or a hole; a coil formed in a shape in which the winding having a lead portion is wound around the bobbin, the coil being molded by resin, and the lead portion penetrating through the slit or the hole; and a plate through which the lead portion of the coil penetrates, the plate contacting with a circumferential edge of the slit or the hole of the flange so as to close the slit or the hole.

A reactor, which enables costs to be reduced while ensuring specific specifications for an electric vehicle such as an HV vehicle, is provided. The reactor for an HV vehicle includes: a reactor core in which a pair of roughly U-shaped core members, which have been integrally formed using an Fe&#x2014;Si magnetic powder, are arranged in a circular shape by aligning two leg sections of each core member opposite to each other with gaps therebetween; and coils wound around the periphery of the leg sections of the core members, which are positioned opposite to each other with the gaps therebetween.

Provided is a reactor which uses a reactor core in which J-shaped iron cores are oppositely disposed in a ring shape. In the ring shape, an axial outer circumferential part of a first coil wound around a first gap and an axial outer circumferential part of a second coil wound around a second gap overlap each other in an axial direction. Regarding four holding stay parts disposed at four corners of the reactor, the rigidity of the holding stay parts close to the first gap and the second gap is lower than the rigidity of the holding stay parts far from the first gap and the second gap.

Reactor and reactor apparatus

The disclosed reactor has a case and a cylindrical molded coil assembly which is disposed inside of the case and which is formed by covering a coil with a resin, wherein the coil assembly is sealed by an iron powder mixed resin to which iron powder has been admixed. The reactor has a pillar provided as a single body with the case, and one or multiple ring-shaped core members. The ring-shaped core members are disposed outside the outer surface of the pillar such that the pillar is inserted inside the inner surface of said ring-shaped core members, and the assembly coil is disposed outside the outer surface of the ring-shaped core members such that the ring-shaped core members are inserted inside the inner surface of said coil assembly. The ring-shaped core members are sealed by means of the aforementioned iron powder-mixed resin.

Growing community of inventors

Toyota, Japan

Nobuki Shinohara