Reactor and reactor manufacturing method, and power converter

Patent metadata

Field	Value
Publication number	US-9449751-B2
Application number	US-201314420192-A
Country	US
Kind code	B2
Filing date	Nov 5, 2013
Priority date	Nov 12, 2012
Publication date	Sep 20, 2016
Grant date	Sep 20, 2016

Abstract

A manufacturing method for a reactor in which resin for covering at least a part of a coil is formed integrally with the coil comprise a step of manufacturing a molded product and a step of attaching a temperature sensor such that the temperature sensor is opposed to a first face. The step of manufacturing the molded product includes following i) to iii): i) arranging the reactor in a cavity space for injection-molding of resin; ii) fixing the coil with the surface of a mold brought into contact with the first face and a second face located at positions which sandwich the coil on the periphery of the coil; and iii) injecting resin into the cavity space to cover at least a coil surface around the first face and a coil surface around the second face with the resin, with the first face and the second face exposed.

First claim

The invention claimed is:

1. A manufacturing method for a reactor in which resin for covering at least a part of a coil is formed integrally with the coil,
the manufacturing method comprising:
a step of manufacturing a molded product including following i) to iii),
i) arranging the reactor in a cavity space for injection-molding of resin,
ii) fixing the coil with surfaces of a mold brought into contact with a first face and a second face, the first face and the second face being located on a periphery of the coil, and the first face and the second face sandwich the coil, and
iii) injecting resin into the cavity space to cover, with resin, at least a coil surface around the first face and a coil surface around the second face with the first face and the second face exposed, and

a step of attaching a temperature sensor such that the temperature sensor is opposed to the first face.

2. The manufacturing method according to claim 1 , wherein
the first face and the second face are provided on side faces of the coil.

3. The manufacturing method according to claim 2 , wherein
a shape of the coil is of a substantially square pole.

4. The manufacturing method according to claim 1 , further comprising:
a step of attaching a radiating member to the second face after the step of manufacturing the molded product.

5. A reactor comprising:
a core;
a coil including a first face and a second face, the first face being a part of a periphery of the coil, and the second face locating at a rear side of the first face;
a cover made of resin, the cover being configured to integrally cover a part of the coil, at least coil surfaces around the first face and the second face being covered with the cover, and the first face and the second face being exposed from the cover; and
a temperature sensor attached such that the temperature sensor is opposed to the first face.

6. The reactor according to claim 5 , wherein
the cover is formed by injection-molding, and
upon injection-molding, the surface of the mold makes contact with the first face and the second face in a cavity space, such that the first face and the second face are exposed.

7. The reactor according to claim 5 , wherein
the first face and the second face are provided on side faces of the coil.

8. The reactor according to claim 7 , wherein
a shape of the coil is of a substantially square pole.

9. The reactor according to claim 5 , further comprising:
a radiating member attached to the second face.

10. The reactor according to claim 9 , wherein
an area of the second face is larger than an area of the first face.

11. The reactor according to claim 5 , further comprising:
an elastic member configured to press the temperature sensor against the first face.

12. The reactor according to claim 11 , further comprising:
a supporting member configured to support the elastic member, wherein
the coil is constituted of two coil bodies arranged such that winding axes of the coil bodies are parallel to each other, and
the supporting member is fixed to the cover between the two coil bodies.

13. The reactor according to claim 5 , further comprising:
a lid that covers the first face, wherein
the temperature sensor is provided in the lid.

14. A power converter comprising:
a capacitor configured to smooth a current;
a substrate;
a reactor including:
a core:
a coil including a first face and a second face, the first face being a part of a periphery of the coil, and the second face locating at a rear side of the first face;
a cover made of resin, the cover being configured to integrally cover a part of the coil, at least coil surfaces around the first face and the second face being covered with the cover, and the first face and the second face being exposed from the cover;
a temperature sensor attached such that the temperature sensor is opposed to the first face;
a lid that covers the first face, the temperature sensor being provided in the lid; and
a third face being a part of the periphery of the coil and exposed from the cover; and

a case which accommodates the capacitors, the substrate, and the reactor,
wherein the first face is located closer to any one of the capacitor and the substrate than the third face.

15. A power converter comprising:
a reactor including
a core:
a coil including a first face and a second face, the first face being a part of a periphery of the coil, and the second face locating at a rear side of the first face;
a cover made of resin, the cover being configured to integrally cover the coil, at least coil surfaces around the first face and the second face being covered with the cover, and the first face and the second face being exposed from the cover;
a temperature sensor attached such that the temperature sensor is opposed to the first face; and

a radiating member attached to the second face of the reactor.

Assignees

• Miyamoto Shingo
• Toyota Motor Co Ltd

Inventors

• Miyamoto Shingo

Classifications

• H01F27/022 Primary

  Encapsulation · CPC title

• H01F41/127

  Encapsulating or impregnating (encapsulating coil and core H01F41/005) · CPC title

• H02M1/42

  Circuits or arrangements for compensating for or adjusting power factor in converters or inverters · CPC title

• H01F27/085 Primary

  Cooling by ambient air · CPC title

• Y10T29/4902

  Electromagnet, transformer or inductor · CPC title