Reactor

Patent metadata

Field	Value
Publication number	US-11842836-B2
Application number	US-201916962737-A
Country	US
Kind code	B2
Filing date	Jan 16, 2019
Priority date	Jan 17, 2018
Publication date	Dec 12, 2023
Grant date	Dec 12, 2023

Abstract

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.

First claim

What is claimed is:

1. A reactor comprising:
a core that comprises at least a pair of T-shaped cores, each having a center protrusion, the at least a pair of T-shaped cores being disposed with a gap therebetween;
a coil attached to a part of the core;
a core molding member which is formed integrally by a resin material and in which the pair of T-shaped cores are embedded;
a housing which houses therein a reactor main body comprising the core, the coil and the core molding member; and
a filler molded portion formed of a filler provided between the reactor main body and the housing,
wherein:
the core molding member comprises a coupling portion that is provided between the pair of T-shaped cores at a location corresponding to the gap, and
the coupling portion is provided with a through-hole filled with the filler, the coupling portion further having a pair of connection portions which face with each other across the through-hole and which connect a space between the pair of T-shaped cores.

2. The reactor according to claim 1 , wherein:
the core is annular; and
the coupling portion is disposed at an inner-circumference side of the annular core.

3. The reactor according to claim 1 ,
a filler molded portion formed of a filler provided between the reactor main body and the housing,
wherein one of the connection portions is provided with an opening in communication with the through-hole.

4. The reactor according to claim 3 , wherein the connection portion comprises a wall portion that comprises pieces standing upright at a location facing each other across the opening.

5. The reactor according to claim 3 , wherein the connection portion comprises an inclined portion formed of a resin material that becomes thin toward the opening.

6. The reactor according to claim 1 , wherein one of the pair of connection portions comprises a pair of opposing connection portions which face with each other via a clearance in an orthogonal direction to a connection direction.

7. The reactor according to claim 6 , wherein the other one of the pair of connection portions is disposed between the opposing connection portions so as to face with each other, and is formed by a width that is equal to or smaller than a clearance between the opposing connection portions.

8. The reactor according to claim 1 , wherein the pair of connection portions comprises respective tabular portions in a direction orthogonal to each other.

9. The reactor according to claim 1 ,
wherein an enlarged portion which a cross-section of a cross-sectional shape of the through-hole is provided at one end portion of the through-hole.

10. The reactor according to claim 1 ,
wherein enlarged portions which are each a cross-section of a cross-sectional shape of the through-hole are provided at both of a pair of end portions of the through-hole.

11. The reactor according to claim 3 , wherein:
the coil includes a pair of partial coils attached across the coupling portion, and
a restriction portion which restricts the clearance between a pair of the partial coils is provided to the core molding member.

12. The reactor according to claim 3 , wherein a communication opening which is in communication with the through-hole and where the core is exposed from the core molding member is provided to the connection portion.

13. A reactor comprising:
a core that comprises at least a pair of partial cores disposed with a gap therebetween;
a coil attached to a part of the core; and
a core molding member which is formed integrally by a resin material and which covers the pair of partial cores,
wherein:
the core molding member comprises a coupling portion that is provided between the pair of partial cores at a location corresponding to the gap,
the coupling portion is provided with a through-hole, the coupling portion further having a pair of connection portions which face with each other across the through-hole and which connect a space between the pair of partial cores,
one of the connection portions comprises a pair of opposing connection portions which face each other via a clearance in a direction which is orthogonal to a connection direction, and
another one of the connection portions is disposed between the opposing connection portions so as to face each other, the another one of the connection portions having a width that is equal to or smaller than the clearance between the opposing connection portions.

Assignees

• Tamura Seisakusho Kk

Inventors

• Suzuki Kotaro
• Uekusa Yasuhiro

Classifications

• H01F27/022 Primary

  Encapsulation · CPC title

• H01F27/24

  Magnetic cores · CPC title

• H01F27/28

  Coils; Windings; Conductive connections · CPC title

• H01F41/0246

  Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36) · CPC title

• H01F41/04

  for manufacturing coils {(coils for transformer or inductances H01F27/28)} · CPC title