Reactor and manufacturing method of reactor

Patent metadata

Field	Value
Publication number	US-9984813-B2
Application number	US-201414890275-A
Country	US
Kind code	B2
Filing date	May 6, 2014
Priority date	May 10, 2013
Publication date	May 29, 2018
Grant date	May 29, 2018

Abstract

A reactor ( 2 ) includes a bobbin ( 10 ). The bobbin is a resin-made bobbin, and has a pair of flanges ( 12 a, 12 b ) that face each other. Coils ( 3 ) are wound around the bobbin between the pair of flanges. Each of a pair of plates ( 20 ) is bridged from the flange on one side, which is one of the pair of flanges, to the flange on the other side, which is one of the pair of flanges. The pair of plates abuts on circumferences of the coils between the pair of flanges. A resin cover ( 40 ) covers one of two outer peripheries of the coils. The two outer peripheries are defined by the pair of plates.

First claim

The invention claimed is:

1. A reactor comprising:
a resin-made bobbin having a pair of flanges that face each other;
a coil wound around the bobbin between the pair of flanges;
a pair of plates mounted on the bobbin so that the pair of plates face each other with the bobbin disposed between the pair of plates, wherein the pair of plates extend from one of the pair of flanges to the other of the pair of flanges and the pair of plates abuts on a circumferential surface of the coil between the pair of flanges so that a first outer periphery region of the circumferential surface of the coil is provided above the pair of plates and a second outer periphery region of the circumferential surface of the coil is provided below the pair of plates; and
a resin cover that covers only one of first and second outer periphery regions of the coil.

2. The reactor according to claim 1 , wherein
each of the pair of plates and the bobbin abut on each other through a wavy surface.

3. The reactor according to claim 1 , wherein the resin cover is formed by injection molding.

4. A manufacturing method for the reactor according to claim 3 , wherein,
inside a die for injection molding, a back surface of each of the pair of plates abuts on a cavity surface of the die, and each of the pair of plates defines the cavity for forming the resin cover, the back surface being a surface of each of the pair of plates on an opposite side of a surface that abut on the coil.

5. The reactor according to claim 1 , wherein
the first outer periphery region is a region on an upper side of the pair of plates, and
the second outer periphery region is a region on a lower side of the pair of plates.

Assignees

• Hirata Shuichi
• Okada Takeshi
• Kamikawa Yoshikazu
• Toyota Motor Co Ltd
• Tokai Kogyo Co Ltd

Inventors

• Hirata Shuichi
• Okada Takeshi
• Kamikawa Yoshikazu

Classifications

• H01F27/327

  Encapsulating or impregnating (encapsulating coil and core H01F27/022) · CPC title

• H01F41/02

  for manufacturing cores, coils, or magnets (H01F41/14 takes precedence; for dynamo-electric machines H02K15/00) · CPC title

• H01F27/325 Primary

  Coil bobbins (formers for coils in general H01F5/02) · CPC title

• H01F41/127

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

• H01F27/2876

  Cooling (cooling transformers and inductances in general H01F27/08) · CPC title