JP7204395B2 - Reactor manufacturing method - Google Patents

Description

The present invention relates to a method of manufacturing a reactor having a structure in which at least a part of a core and a coil is covered with resin.

As a method for manufacturing a reactor used in a power conversion device, etc., the core of the reactor is supported by a hanging jig so as to be sandwiched from both sides, the core and coil are accommodated in a mold, and a resin part is formed so as to cover the coil and core. A manufacturing method of molding is known (see Patent Document 1). A reactor is also known in which a holding portion for supporting the reactor is provided on the upper surface of a resin case that covers the core (see Patent Document 2). A primary molding process in which two U-shaped cores are covered with a resin portion except for the end faces of their leg portions, and a second step in which two series of coils are attached to the leg portions of the core and then the coils are covered with a resin portion. A reactor manufacturing method including a subsequent molding step is also known (see Patent Document 3).

Japanese Unexamined Patent Application Publication No. 2011-211043 JP 2010-118423 A JP 2013-149841 A

As in the manufacturing method of Patent Document 1, when the core of the reactor is supported by jigs so as to be sandwiched from both sides, the jigs protrude outside the core. In order to accommodate the core and coil in the molding die in that state, it is necessary to open the molding die widely according to the protrusion of the jig. Therefore, there may arise problems such as an increase in the size of the mold, or an increase in the time required to open and close the mold, resulting in a decrease in productivity.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a reactor manufacturing method capable of reducing the opening amount of a molding die when a core and a coil are housed in the molding die.

A method for manufacturing a reactor according to an aspect of the present invention includes a first step of molding a first resin portion so as to cover at least a portion of each of two cores having a pair of legs and a joint portion connecting the legs; , in a state in which an assembly is constructed by assembling two series of coils to the leg portions of the two cores having the first resin portions formed thereon and combining the cores so that the end surfaces of the leg portions face each other; and a second step of molding a second resin portion so as to cover at least a part of each of the two coils, wherein the first step corresponds to each of the two cores. The first resin portion is molded so that a support portion is provided at a position on the rear surface side with respect to the accommodation direction of the assembly in the mold used in the second step, and in the second step, the The assembly is accommodated in the molding die while supporting the assembly by supporting the support portion with a jig , and the support portion has the above-mentioned A support portion is provided so as to fit within an outer peripheral contour of the assembly excluding the support portion, and the jig is configured such that when the assembly is observed along the housing direction, the support portion is located on the outer periphery of the assembly. It is arranged so as to fit within the outline .

FIG. 4 is a perspective view showing an example of an intermediate reactor assembly at a stage before the coil is covered with resin; 2 is a front view of the assembly of FIG. 1; FIG. 2 is a plan view of the assembly of FIG. 1; FIG. The perspective view which shows the state which looked at the assembly of FIG. 1 from the back side of the same figure. FIG. 2 is a diagram showing an example of a procedure for housing the assembly of FIG. 1 in a mold;

Hereinafter, a method for manufacturing a reactor according to one embodiment of the present invention will be described with reference to the accompanying drawings. The manufacturing method of the present embodiment includes a first step of covering at least a portion of the core of the reactor with a resin; and a second step of covering with. 1 to 4 show an assembly 3 obtained by assembling two series of coils 2 to two molded products 1A and 1B (hereinafter sometimes represented by reference numeral 1) obtained in the first step. shows an example of The assembly 3 is an intermediate or preliminary assembly part corresponding to the reactor as a finished product that is finally manufactured.

One molded product 1A is obtained by integrally molding a core mold 5A, which is an example of a first resin portion, with one of the two cores 4 indicated by broken lines in FIGS. 2 and 3 by an insert molding method. The other molded product 1B is obtained by integrally molding a core mold 5B, which is an example of a first resin portion, with the other of the two cores 4 indicated by broken lines in FIGS. 2 and 3 by an insert molding method. Each core 4 is made of iron as an example. The core 4 may be of a common shape and size between the moldings 1A, 1B. One core 4 has a substantially U-shaped configuration in which one end portions of a pair of parallel leg portions 4a are connected to each other by a connecting portion 4b. One assembly 3 includes two cores 4 by constructing the assembly 3 using two molded products 1A and 1B.

In the first step, each of core molds 5A and 5B (hereinafter sometimes represented by reference numeral 5) is molded so as to cover the outer surface of core 4 excluding tip surface 4c. The core mold 5 is molded using an insert molding method in which a resin is injected into the mold while the core 4 is accommodated in the mold as an insert part, for example. Molding of the core mold 5 may be performed for each core 4 . That is, the molded products 1A and 1B do not need to be molded at the same time. The first step includes the entire procedure of individually molding the core mold 5A or 5B on the core 4 to manufacture the molded product 1A or 1B. 1 to 4 show a portion of the core mold 5 covering the connecting portion 4b. An opening 5 a may be formed at an appropriate position of the core mold 5 to expose the core 4 .

In the second step, the core 4 on which the core mold 5A is formed and the core 4 on which the core mold 5B is formed are positioned on the tip end surface 4c of the leg portion 4a, that is, the end surface located on the opposite side to the connecting portion 4b. are combined so as to face each other. In FIG. 3, a solid line shows a state in which the coil 2 is partially cut away and the tip surfaces 4c face each other. An intervening component such as a gap body 6 having a magnetic permeability smaller than that of the core 4 may be arranged between the tip surfaces 4c. When the cores 4 are combined, the coils 2 are fitted around the outer circumferences of the leg portions 4a of the cores 4. As shown in FIG. In this case, the legs 4 a may be covered with the core mold 5 . Each coil 2 is formed by winding a conductor material around a predetermined winding axis RA (see FIG. 1) a given number of times. The winding axis RA of the coil 2 fitted to the core 4 coincides with the extending direction of the leg portion 4a (horizontal direction in FIG. 3) and is parallel to each other.

Terminal portions 2a and 2b for connection are led out from each coil 2 in the same direction. As an example, the terminal portions 2a and 2b are drawn out of the assembly 3 (upward in the illustrated example) along a direction substantially perpendicular to the winding axis RA at one end of the coil 2 in the direction of the winding axis RA. Also, the two coils 2 are connected to each other by a coil connecting portion 2c. As an example, the coil connecting portion 2c is located on the other end side of the coil 2 in the direction along the winding axis RA, that is, on the side opposite to the side on which the terminal portions 2a and 2b are provided. provided so as to protrude outside and in the same direction as the

By fitting the coil 2 to the core 4 and abutting the cores 4 together, the assembly 3 shown in FIGS. 1 to 4 is obtained. The assembly 3 is housed in a predetermined molding die, and a coil mold 7 (shown in phantom lines in FIG. 1) as an example of a second resin portion is formed in the molding die so as to cover at least a portion of the coil 2. is molded. Thereby, a reactor is manufactured. However, the reactor may be manufactured by adding a further step after the second step. Concerning the accommodation of the assembly 3 in the mold in the second step, a specific example will be given and explained later.

In the second step, it is necessary to accommodate the assembly 3 in the mold while maintaining the state in which the two cores 4 and the coil 2 are combined as shown. In order to facilitate the accommodating work, in the first step, the core molds 5A and 5B corresponding to the two cores 4 are formed such that the support portions 10 are provided on each of the core molds 5A and 5B. For example, a single support portion 10 is formed in one core mold 5A on the side closer to the coil connection portion 2c, and two support portions 10 are formed in the core mold 5B on the opposite side.

As an example, the support portion 10 is formed by forming protrusions 10a and 10b that protrude in a flat plate shape along the end surfaces of the coil 2 on the core molds 5A and 5B, respectively. It is formed by providing recesses 10c along the direction. The recessed portion 10c may be formed in the shape of a through hole. As is clear from FIGS. 1 and 2, the protruding portion 10a of the one core mold 5A has a generally triangular flat plate shape. As is clear from FIG. 4, in the other core mold 5B, the projecting portion 10b is formed in a flange shape extending along the end surfaces of the two coils 2 over substantially the entire width of the core mold 5B. Therefore, the protrusion 10b is shared between the two support portions 10 of the core mold 5B. However, in the core mold 5B as well, an independent projection 10a may be provided for each support portion 10 in the same manner as the projection 10a of the core mold 5A.

In one core mold 5A, the support portion 10 is provided on the upper surface 5b side of the core mold 5A and at a position avoiding the coil connecting portion 2c in the direction along the end surface of the coil 2. As shown in FIG. The upper surface 5b is the rear surface of the core mold 5A with respect to the accommodation direction when the assembly 3 is accommodated in the mold used in the second step downward in FIG. 2 (direction of arrow D). . In this case, the housing direction is opposite to the direction in which the terminal portions 2a and 2b and the coil connecting portion 2c protrude from the coil 2, and the upper surface 5b protrudes the terminal portions 2a and 2b and the coil connecting portion 2c from the coil 2. It is a face oriented in the same direction as the direction. Therefore, as is clear from FIG. 3, the support portion 10 is formed so as to fit within the contour of the outer periphery of the assembly 3 when the assembly 3 is viewed downward along the housing direction.

As is clear from FIG. 3, part of the coil connecting portion 2c protrudes outward from the coil 2 in the direction along the winding axis RA (the side closer to the outer shape of the assembly 3). That is, when looking down on the assembly 3 along the housing direction, part of the coil connecting portion 2c overlaps with the upper surface 5b of the core mold 5A. Therefore, in the core mold 5A, the support part 10 can be brought as close to the end surface of the coil 2 as possible by providing the support part 10 at a position avoiding the coil connecting part 2c. Accordingly, there is no possibility that the outer shape of the reactor to be finally obtained will be substantially enlarged by the support portion 10 . That is, when the support portion 10 is provided at a position overlapping with the coil connection portion 2c, in order to avoid interference between the support portion 10 and the coil connection portion 2c, the support portion 10 is positioned at the coil connection portion 2c with respect to the direction of the winding axis RA. should be placed outside. In that case, the support portion 10 protrudes outside the coil connecting portion 2c in a region above the upper surface 5b of the core mold 5A. Therefore, at least part of the outer shape of the reactor is defined by the support portions 10 , and as a result, the outer shape of the reactor is enlarged by the support portions 10 . However, if the support portion 10 is provided at a position avoiding the coil connection portion 2c as described above, there is no need to arrange the support portion 10 outside the coil connection portion 2c, which is advantageous in reducing the size of the reactor. is. Regarding the core mold 5B on the opposite side, since the coil connection portion 2c does not exist on the same side, it is not necessary to determine the position of the support portion 10 in relation to the coil connection portion 2c. However, if the coil connecting portion 2c exists on the core mold 5B side in addition to or instead of the core mold 5A side, the position of the support portion 10 of the core mold 5B is determined in the same manner as the core mold 5A side. you can

FIG. 5 shows an example of the procedure for housing the assembly 3 in the mold 20 to be used in the second step. In the illustrated example, the arm portion 21a of the jig 21 is attached to each support portion 10 of the core molds 5A and 5B. Thereby, the assembly 3 is supported such that the core molds 5A and 5B are suspended between the arm portions 21a. The jig 21 is arranged so as to fit within the contour of the outer circumference of the assembly 3 when the assembly 3 is observed along the accommodating direction. With the assembly 3 supported by the jig 21, the assembly 3 and the jig 21 are integrally lowered into the molding die 20 along the accommodation direction indicated by the arrow D. are housed in After that, the jig 21 is removed, the mold 20 is closed, and molding in the second step is started.

In the above procedure, since the supporting portion 10 is formed near the end surface of the coil 2, the jig 21 is arranged so as not to protrude from the outer circumference of the assembly 3, and the assembly 3 is housed in the molding die. It is possible. Therefore, the gap amount G between both ends of the assembly 3 and the molding die 20 when the molding die 20 is opened can be reduced to a range necessary for passage of the assembly 3 . As a result, it is possible to reduce the size of the mold 20 or shorten the time required to open and close the mold 20, thereby improving productivity.

The present invention is not limited to the above embodiments, and may be implemented in various modified or changed forms. For example, the shape of the supporting part is not limited to the illustrated example, and when the core and the coil are housed in the molding die in the second step, the state in which the core and the coil are assembled in cooperation with the supporting jig It may be formed into various shapes as long as it is possible to maintain the The supporting portion is not limited to the supporting portion having a recess or a through hole, and the supporting portion may be formed to have various shapes such as a hook shape and a projection shape. That is, the supporting portion may have any shape as long as it can support the assembly including the core and the coil when it is accommodated in the molding die in the second step. , meshing, insertion, hooking, etc., which can be used to support mechanical parts, can be selected as appropriate. The assembly shape of the core and coil in the second step is not limited to the illustrated example, and can be changed as appropriate according to the shape of the reactor to be finally manufactured. For example, the shapes of the core molds 5A and 5B and the extent to which the core molds 5A and 5B cover the core 4 may be changed as appropriate. The position, shape, or arrangement of the coil connecting portion may also be changed as appropriate. In addition, the shape of the coil or core may be changed as appropriate.

Aspects of the present invention derived from the above-described embodiment and modifications will be described below. In the following description, reference numerals in the drawings are added in parentheses, but this does not limit the embodiments of the present invention to the illustrated forms.

A method for manufacturing a reactor according to an aspect of the present invention includes a first reactor so as to cover at least a part of each of two cores (4) having a pair of legs (4a) and a joint (4b) connecting the legs (4a). a first step of molding the resin portions (5A, 5B); and attaching the two coils (2) to the leg portions of the two cores on which the first resin portions are molded, while attaching each core to the leg portions. A second step of forming a second resin part (7) so as to cover at least a part of each of the two series of coils in a state in which the end surfaces (4c) are combined so as to face each other to form an assembly (3). wherein, in the first step, the first resin portions corresponding to the two cores are placed in the mold (20) used in the second step; The support portion (10) is provided at a position on the rear surface side (upper surface 5b side) with respect to the housing direction of the assembly ( the direction of arrow D in FIGS. 2 and 5), and in the second step, the support portion (10) is formed. The assembly is accommodated in the molding die while supporting the assembly by supporting the assembly with a jig (21) , and when the support part observes the assembly along the accommodation direction, The support portion is provided so as to be accommodated within an outer peripheral contour of the assembly excluding the support portion, and the jig is configured such that when the assembly is observed along the housing direction, the support portion is the same as that of the assembly. It is arranged to fit within the outer contour .

According to the above aspect, when the core and the coil are assembled to be housed in the molding die in the second step, when the assembly is observed along the housing direction, the first resin portion formed on each core is A support is positioned to fit within the outer contour of the assembly. Therefore, if the core is supported using these support portions, fixtures such as jigs necessary for supporting the core can be accommodated within the outer contour of the assembly, or even if the fixtures protrude from the outer contour, the core can still be accommodated. The amount of protrusion can be reduced as compared with the case where both sides of are sandwiched. Therefore, it is possible to reduce the amount of opening in the molding die when housing the assembly, to reduce the size of the molding die, or to shorten the time required for opening and closing the molding die, thereby improving productivity. is obtained.

In the above aspect, when the coil connecting portion (2c) connecting the two coils is provided on at least one end face side in the direction along the winding axis (RA) of each coil, the coil connecting portion and The support portions of the first resin portion (5A) located on the same side may be formed at positions offset in the direction along the end surface of the coil with respect to the coil connecting portion. According to this, it is possible to avoid the interference between the coil connection portion and the support portion while suppressing the expansion of the outer shape of the reactor due to the provision of the support portion. In the second step, an assembly (3) in which the core and the coil are combined is supported by a jig (31) attached to the support portion, and the jig moves the assembly in the accommodating direction. It may be arranged to fit within the outer contour of the assembly when viewed along. According to this, the core and coil can be accommodated in the mold by opening the mold to the extent necessary to pass the outer peripheral contour of the assembly. Thereby, it is possible to minimize the opening amount of the mold.

1A, 1B Molded product in the first step 2 Coil 2c Coil connecting portion 3 Assembly 4 Core 4a Leg portion of core 4b Coupling portion of core 4c End surface of leg portion 5A, 5B Core mold 5b Upper surface of core mold 7 Coil mold 10 Supporting part 20 Mold 21 Jig

Claims (1)

a first step of molding a first resin portion so as to cover at least a portion of each of two cores having a pair of legs and a connecting portion connecting the legs; In a state in which two coils are assembled to the leg portions of the core and the respective cores are combined so that the end faces of the leg portions face each other to form an assembly, the coils cover at least a part of each of the two coils. and a second step of molding the second resin portion in the reactor manufacturing method,
In the first step, the first resin portion corresponding to each of the two cores is provided with a support portion at a position on the rear surface side with respect to the housing direction of the assembly in the molding die used in the second step. Molded so that it can be
In the second step, the assembly is accommodated in the molding die while supporting the assembly by supporting the support portion with a jig ;
The support portion is provided so that the support portion fits within an outer peripheral contour of the assembly excluding the support portion when the assembly is observed along the housing direction,
The jig is arranged such that the support portion is contained within the outer contour of the assembly when the assembly is observed along the housing direction.
A manufacturing method of a reactor.

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