REACTOR AND METHOD OF MANUFACTURING THE SAME

• US 20130088317A1
• Filed: 05/08/2012
• Published: 04/11/2013
• Est. Priority Date: 10/11/2011
• Status: Abandoned Application

• Current Assignee: Sumitomo Wiring Systems Limited (Sumitomo Corporation)
• Original Assignee: Sumitomo Wiring Systems Limited (Sumitomo Corporation)
• Inventors: Onizuka, Takahiro, Ooishi, Akinori, Tawara, Hideo, Yabutani, Hiromi
• Application Number:
  US13/466,171
• Publication Number:
  US 20130088317A1
• Time in Patent Office: Days
• US Class Current: 336/212
• CPC Class Codes: H01F 17/06 with core substantially closed in itself, e.g. toroid
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/263 Fastening parts of the core together
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 27/325 Coil bobbins formers for coils in general H01F5/02
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

An annular core (14) of a reactor (10) has two core mold members (24a, 24b) integrated by bonding core segments (32) and gap plates (34) with a cyanoacrylate-based adhesive agent (36) to each other and insert-molding the bonded core segments (32) and gap plates (34) with a thermoplastic resin (38).

Claims

1. A reactor (10;

60;

70;

80) comprising an annular core (14) having a plurality of core segments (32) and at least one gap plate (34) interposed between the core segments (32), and a coil (12) wound around the annular core (14), wherein

the annular core (14) includes at least one core mold member formed integrally by bonding the core segments (32) and the gap plate (34) to each other with a cyanoacrylate-based adhesive agent (36), and insert-molding the core segments (32) and the gap plate (34) with a thermoplastic resin (38) to define a unitary matrix of the thermoplastic resin (38) surrounding parts of the core segments (32) and the gap plate (34).

2. The reactor of claim 1, wherein the at least one core mold member comprises two core mold members defining inner cores (24a, 24b) having the coil (12) wound thereon, the annular core (14) further comprises two outer cores (26a, 26b) coupling ends of the inner cores (24a, 24b) to each other.

3. The reactor of claim 2, wherein the core mold members are substantially identical and each further comprises a side bobbin (44a, 44b) integrated with one of the inner cores (24a, 24b), the side bobbins (44a, 44b) being configured to position the outer cores (26a, 26b) with respect to the inner cores (24a, 24b).

4. The reactor of claim 3, wherein each of the core mold members further comprises one of the outer cores (26a, 26b) integrated with one of the inner cores (24a, 24b) and one of the side bobbin (44a, 44b).

5. The reactor of claim 4, wherein the core mold members are identical.

6. The reactor of claim 1, wherein the at least one gap plate (34) comprises a plurality of gap plates (34).

7. The reactor of claim 1, wherein the core mold member comprises two inner cores (24a, 24b) each having the core segments (32) and the gap plate (34) and having the coil (12) wound thereon, the core mold member further having a first outer core (26a) coupling first ends of the inner cores (24a, 24b) and the annular core (14) further comprising a second outer core (26b) coupling second ends of the inner cores (24a, 24b).

8. A method of manufacturing a reactor (10, 60, 70, 80) including an annular core (14), the method comprising:

bonding core segments (32) and at least one gap plate (34) in an alternating laminated array using a cyanoacrylate-based adhesive agent (36);

molding a thermoplastic resin (38) around at least parts of the laminated array of the core segments (32) and at least one gap plate (34) to form at least one core molding member;

inserting at least part of the core molding member into a coil (12); and

assembling the core molding member with at least one other core (24a, 24b, 26a, 26b) to form the annular core (14).

9. The method of claim 8, wherein the step of molding the thermoplastic resin (38) comprises molding at least one side bobbin (44a, 44b) that is configured to mate with at least one outer core (26a, 26b).

10. The method of claim 8, wherein the step of molding the thermoplastic resin (38) comprises molding the thermoplastic resin (38) at least partly around an outer core (26a, 26b).