Reactor

• US 8,659,381 B2
• Filed: 03/07/2013
• Issued: 02/25/2014
• Est. Priority Date: 08/31/2009
• Status: Active Grant

• Current Assignee: Sumitomo Electric Industries Limited (Sumitomo Corporation)
• Original Assignee: Sumitomo Electric Industries Limited (Sumitomo Corporation)
• Inventors: Yoshikawa, Kouhei, Yamamoto, Shinichiro
• Primary Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US13/789,060
• Publication Number:
  US 20130181801A1
• Time in Patent Office: 355 Days
• Field of Search: 336/65, 336/200, 336/212, 336233-234, 336180-184, 336/96
• US Class Current: 336/180
• CPC Class Codes: H01F 27/022 Encapsulation
• CPC Class Codes: H01F 27/263 Fastening parts of the core together
• CPC Class Codes: H01F 27/30 Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 37/00 Fixed inductances not covered by group H01F17/00

Abstract

To provide a reactor with which resin can fully be packed between a core and a coil with ease, and in which the core can easily be handled when the reactor is manufactured.

The reactor includes: a coil 10 formed with paired coil elements 10A and 10B that are made of a spirally wound wire, the coil elements being coupled to each other in a paralleled state; internal core portions 22 that are fitted into the coil elements 10A and 10B to structure a part of an annular core 20; and exposed core portions 24 that are exposed outside the coil elements 10A and 10B to couple the internal core portions 22 to each other, to thereby form the rest of the annular core 20. The reactor includes an external resin portion that covers at least a part of an assembled product 1A made up of the coil 10 and the core 20. In each of the exposed core portions 24, a cut-out corner portion 24g is provided to at least part of a joining portion of an inner end face 24f facing the end face of the coil and an adjacent face (side face 24s) that is continuous to the inner end face 24f, whereby the resin can easily be packed between the coil 10 and the core 20, and it becomes possible to prevent chipping off when handled.

Claims

1. A reactor, comprising:

a coil formed with paired coil elements that are made of a spirally wound wire, the coil elements being coupled to each other in a paralleled state;

internal core portions that are fitted into the paired coil elements to structure a part of an annular core;

exposed core portions that are exposed outside the coil elements to couple the internal core portions to each other, to thereby form a rest of the annular core; and

an external resin portion that covers at least a part of an assembled product made up of the coil and the core, wherein

in each of the exposed core portions, a cut-out corner portion is provided to at least a part of a joining portion of an inner end face facing an end face of the coil and an adjacent face that is continuous to the inner end face,

the adjacent face of each of the exposed core portions is a side face adjacent to the inner end face,

the cut-out corner portion is structured with a curved surface, an arc-radius of the surface is 1 mm or more and 10 mm or less.

2. A reactor, comprising:

a coil formed with paired coil elements that are made of a spirally wound wire, the coil elements being coupled to each other in a paralleled state;

internal core portions that are fitted into the paired coil elements to structure a part of an annular core;

exposed core portions that are exposed outside the coil elements to couple the internal core portions to each other, to thereby form a rest of the annular core; and

an external resin portion that covers at least a part of an assembled product made up of the coil and the core, wherein

in each of the exposed core portions, a cut-out corner portion is provided to at least a part of a joining portion of an inner end face facing an end face of the coil and an adjacent face that is continuous to the inner end face,

the adjacent face of each of the exposed core portions is a side face adjacent to the inner end face,

the cut-out corner portion is structured with a flat surface.

3. A converter including a reactor as one of a component for the converter,

the reactor comprising:

a coil formed with paired coil elements that are made of a spirally wound wire, the coil elements being coupled to each other in a paralleled state;

internal core portions that are fitted into the paired coil elements to structure a part of an annular core;

exposed core portions that are exposed outside the coil elements to couple the internal core portions to each other, to thereby form a rest of the annular core; and

an external resin portion that covers at least a part of an assembled product made up of the coil and the core, wherein

in each of the exposed core portions, a cut-out corner portion is provided to at least a part of a joining portion of an inner end face facing an end face of the coil and an adjacent face that is continuous to the inner end face.

4. A power conversion device including the converter according to claim 3.