Manufacturing method of a reactor

• US 9,679,694 B2
• Filed: 12/17/2013
• Issued: 06/13/2017
• Est. Priority Date: 12/21/2012
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Atsumi, Takashi, Shinohara, Nobuki, Okada, Takeshi, Kitami, Akio
• Primary Examiner(s): Kim, Paul D
• Application Number:
  US14/437,795
• Publication Number:
  US 20150279550A1
• Time in Patent Office: 1,274 Days
• CPC Class Codes: H01F 2027/406 Temperature sensor or protection
• CPC Class Codes: H01F 27/022 Encapsulation
• CPC Class Codes: H01F 27/22 Cooling by heat conduction through solid or powdered fillings
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/266 Fastening or mounting the core on casing or support on coil H01F27/30
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2876 Cooling cooling transformers and inductances in general H01F27/08
• 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 27/323 Insulation between winding turns, between winding layers
• CPC Class Codes: H01F 27/325 Coil bobbins formers for coils in general H01F5/02
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• CPC Class Codes: H01F 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A manufacturing method of a reactor includes: assembling an assembly constituted by a coil and a bobbin by inserting the bobbin, which includes a tube portion and a flange portion, through the coil so that a tip of the tube portion protrudes from the coil; forming a cavity by installing the assembly in a first die so that a portion of a coil lateral face comes into contact with a cavity face of the first die, and closing a second die so that the second die is opposed to the first die; and extending first press rods from a cavity face of the second die toward the bobbin in the cavity, and injecting a resin into the cavity while pressing both ends of the bobbin in an axial direction of the coil from an opposite side to the portion of the coil lateral face.

Claims

1. A manufacturing method of a reactor, comprising:

assembling an assembly constituted by a coil and a bobbin which bobbin includes a tube portion and a flange portion, by inserting the bobbin, through the coil so that a tip of the tube portion protrudes from the coil;

forming a cavity by installing the assembly in a first die so that a portion of a coil lateral face comes into contact with a cavity face of the first die, and closing a second die so that the second die is opposed to the first die; and

inserting first press rods into the cavity to reach the bobbin through a cavity face of the second die, and injecting a resin into the cavity while pressing, from an opposite side of the tube portion from the portion of the coil lateral face, both ends of the bobbin in an axial direction of the coil with the first press rods.

2. The manufacturing method according to claim 1, further comprising:

inserting second press rods into the cavity to reach a portion of a core through the cavity face of the second die, the portion of the core protruding from both the ends of the bobbin in the axial direction of the coil; and

pressing both ends of the core in the axial direction of the coil from the opposite side against the cavity face of the first die with the second press rods while injecting the resin into the cavity.

3. The manufacturing method according to claim 2, wherein

the first die is provided with a recess, and

while injecting the resin into the cavity, the both ends of the core are pressed against the cavity face of the first die such that the portion of the coil lateral face is in contact with the recess and is exposed from a resinous cover formed by injecting the resin into the cavity.

4. The manufacturing method according to claim 2, further comprising:

inserting a first core part and a second core part into the tube portion so as to be opposed to each other inside the bobbin, the first core part and the second core part constituting the core; and

filling a gap between the first core part and the second core part inside the bobbin with an adhesive, wherein

the resin is injected into the cavity before the adhesive is solidified.

5. The manufacturing method according to claim 4, further comprising

providing an inner flange on an inner face of the tube portion of the bobbin, the inner flange having a ring shape and being configured to ensure the gap.

6. The manufacturing method according to claim 1, further comprising:

fixing the flange portion to a first end of the tube portion;

providing the bobbin with a plate portion that extends from a second end of the tube portion in an axial direction of the tube portion, wherein

the flange portion and the plate portion are pressed by the first press rods while the resin is injected into the cavity.