CN112185669B

CN112185669B - Skeleton for reactor, and method for manufacturing reactor

Info

Publication number: CN112185669B
Application number: CN202010600693.3A
Authority: CN
Inventors: 川岛浩
Original assignee: Sumida Group Co ltd
Current assignee: Sumida Group Co ltd
Priority date: 2019-07-05
Filing date: 2020-06-28
Publication date: 2024-05-03
Anticipated expiration: 2040-06-28
Also published as: CN112185669A

Abstract

The invention provides a framework for a reactor, a reactor using the framework for the reactor and a manufacturing method of the reactor, wherein the space for arranging coils in a winding state is easy to adjust according to the size of the coils. The reactor skeleton (120) is configured to be provided with: a skeleton main body part (121) which is configured by extending a fixing flange part (121B) outward at one end part of a hollow cylindrical trunk part (121A); and an attachment flange portion (122) that is attached to the other end portion of the trunk portion (121A) after the coil is disposed, and that is capable of disposing a coil (110) in a wound state around the trunk portion (121A) between the fixing flange portion (121B) and the attachment flange portion (122).

Description

Skeleton for reactor, and method for manufacturing reactor

Technical Field

The present invention relates to a reactor frame constituting a reactor used in circuits of various devices, a reactor using the reactor frame, and a method for manufacturing the reactor.

Background

The reactor is provided with: a coil configured by winding an electric wire; a hollow cylindrical reactor bobbin penetrating through the hollow portion of the coil; and a magnetic core having a leg portion penetrating through an inner hollow portion of the reactor frame, the reactor frame being made of an insulating material to obtain insulation between the coil and the magnetic core. As a reactor frame, it is proposed to form a frame structure member in a shape in which a cylindrical body is divided into two at a predetermined position in an axial direction of the cylindrical body, and to combine the frame structure members in a state of passing through a hollow portion of a coil wound body to form a cylindrical structure (for example, refer to patent document 1 and patent document 2).

Prior art literature

Patent literature

Patent document 1: japanese patent laid-open publication No. 2011-198847

Patent document 2: japanese patent application laid-open No. 2012-070001

However, in the reactor frame described in the above patent document, in the assembly work, it is necessary to perform a work of connecting two frame structure members each having flange portions at both ends thereof in the hollow portion of the coil. At this time, the connecting portion is hardly visible from the outside of the coil, and therefore, there is a difficulty in working. In addition, the flange portions are fixed to the respective frame members, and the distance between the flange portions, in other words, the size of the space in which the coil is arranged in a wound state cannot be changed. Therefore, even if the length of the coil is within the tolerance in design, there is a risk that: the distance between the flange portions is too narrow to dispose the coil, or an excessive load is applied to the flange portions, or the distance between the flange portions is too wide to shake the coil. When the length of the coil in design is changed by changing the specification such as the number of turns, the reactor frame may need to be designed and manufactured again.

In particular, in an edgewise coil wound with a flat wire, the winding is one layer, and therefore the length of a coil assembly portion of a bobbin for a reactor to which the edgewise coil is assembled in a wound state is made large in consideration of the thickness tolerance (for example, ±0.13mm×the number of windings) of the wire. In this case, although varnish (varnish) or the like is filled between the bobbin and the coil to fix the coil, since the edgewise coil is hollow, when the difference between the coil length and the length of the coil mounting portion is large, the fixation of the coil is separated by vibration or the like, and various adverse phenomena in terms of product and performance occur.

Disclosure of Invention

Problems to be solved by the invention

In view of the above, an object of the present invention is to provide a reactor frame in which a space in which a coil is assembled in a wound state can be adjusted according to the size of the coil, a reactor using the reactor frame, and a method for manufacturing the reactor.

Means for solving the problems

In order to solve the above problems, a reactor frame, a reactor, and a method for manufacturing a reactor according to the present invention have the following features.

First, a reactor frame according to claim 1 of the present invention includes: a main body portion which has a hollow cylindrical shape and is capable of being provided with a coil in a wound state on an outer peripheral portion; and flange portions provided at both ends of the main body, wherein at least one of the flange portions provided at both ends is a fitting flange portion that can be fitted after the coil is disposed.

Next, a first group of the present invention is a reactor frame including: a main body portion which has a hollow cylindrical shape and is capable of being provided with a coil in a wound state on an outer peripheral portion; and flange portions provided at both ends of the main body, wherein the flange portion provided at one end is a fixed flange portion fixed to the main body, and the flange portion provided at the other end is an assembly flange portion capable of being assembled after the coil is disposed at the main body.

The above shows a preferable embodiment of the first group of the reactor frame of the present invention.

The first group of the reactor frame is characterized in that the fitting flange portion includes an engagement portion engaged with the trunk portion, the other end portion of the trunk portion includes an engagement receiving portion for engaging with the engagement portion, and the engagement portion and the engagement receiving portion are engaged by selecting engagement positions of each other, whereby the interval between the fixing flange portion and the fitting flange portion can be adjusted.

More preferably, at least one of the engaging portion and the engaging receiving portion is formed in plurality so as to be different in position from the fixing flange portion.

In this case, the engagement receiving portion may be provided on an outer peripheral surface of the trunk portion.

The reactor frame may further include an engagement limiting portion that can maintain an engaged state between the engagement portion and the engagement receiving portion.

In the case where the reactor frame includes a pair of the trunk portions arranged in parallel, it is preferable that the fixing flange portion is provided at one end portion of each of the trunk portions, and the fitting flange portion is fitted to the other end portion of each of the trunk portions from the adjacent side.

In the case of providing the plurality of trunk portions arranged in parallel, at least one of the fixing flange portion fixed to one end portion of each trunk portion and the fitting flange portion fitted to the other end portion of each trunk portion may be integrated.

Next, a second group of the present invention is a reactor frame including: a main body portion which has a hollow cylindrical shape and is capable of being provided with a coil in a wound state on an outer peripheral portion; and flange portions provided at both end portions of the trunk portion, the flange portions provided at both end portions being fitting flange portions capable of fitting to the trunk portion.

The above shows a preferable embodiment of the second group reactor frame of the present invention.

Preferably, the fitting flange portion includes engaging portions engaged with the trunk portion, and both ends of the trunk portion include engaging receiving portions for engaging with the engaging portions, respectively, and the interval between the fitting flange portions can be adjusted by selecting and engaging positions of the engaging portions and the engaging receiving portions.

More preferably, at least one of the engaging portion and the engaging receiving portion is formed in plurality so as to have different positions in the axial direction of the trunk portion.

Preferably, the reactor frame includes a pair of the trunk portions arranged in parallel, and the fitting flange portions are fitted to at least one end portion of each trunk portion from adjacent sides.

In the case where the reactor frame includes a plurality of the trunk portions arranged in parallel, at least one of the fitting flange portion fitted to one end portion of each trunk portion and the fitting flange portion fitted to the other end portion of each trunk portion may be integrated.

Further, in the reactor according to the present invention, the coil is disposed around the trunk portion of each reactor frame in a wound state, and the magnetic core is assembled so that the leg portion of the magnetic core is housed in the hollow portion of the trunk portion.

Further, a first method of manufacturing a reactor according to the present invention is a method of manufacturing a reactor in which a coil is disposed around a trunk portion of a reactor frame in a wound state, and a magnetic core is assembled so that leg portions of the magnetic core are accommodated in a hollow portion of the trunk portion, the reactor frame including flange portions at both end portions of the trunk portion having a hollow cylindrical shape, the method comprising: a skeleton forming step of forming a skeleton main body portion having a fixing flange portion at one end of the main body portion and an attachment flange portion attached to the other end of the main body portion; a coil forming step of winding an electric wire to form a coil; a coil mounting step of passing the trunk portion through an air core portion of the coil to mount the coil around the trunk portion; a flange portion assembling step of assembling the flange portion at a predetermined position of the other end portion of the trunk portion to which the coil is attached; and a core assembly step of assembling the magnetic core so as to accommodate the leg portions of the magnetic core in the hollow portion of the main portion provided with the coil and the fitting flange portion.

Further, a second method of manufacturing a reactor according to the present invention is a method of manufacturing a reactor in which a coil is disposed around a trunk portion of a reactor frame in a wound state, the magnetic core is assembled so as to accommodate leg portions of the magnetic core in a hollow portion of the trunk portion, and the reactor frame includes flange portions at both end portions of the trunk portion having a hollow cylindrical shape, the method including: a skeleton forming step of forming the main body portion and the flange portions respectively fitted to both end portions of the main body portion, that is, fitting flange portions; a coil forming step of winding an electric wire to form a coil; a first flange portion assembling step of assembling one of the flange portions at a predetermined position of one end portion of the main portion; a coil mounting step of passing the trunk portion through an air core portion of the coil to mount the coil around the trunk portion; a second flange portion mounting step of mounting the other one of the mounting flange portions at a predetermined position of the other end portion of the main body portion, to which the coil is mounted and to which the one of the mounting flange portions is mounted; and a core assembly step of assembling the magnetic core so as to house the leg portions of the magnetic core in the hollow portion of the main portion provided with the coil and the fitting flange portion.

The "first flange portion assembling step", "coil mounting step", and "second flange portion assembling step" may be performed sequentially, or may be performed after the order of the "first flange portion assembling step" and the "coil mounting step" is changed from one another.

Effects of the invention

According to the present invention, a reactor frame and a reactor include: a main body portion which has a hollow cylindrical shape and is capable of being provided with a coil in a wound state on an outer peripheral portion; and flange parts provided at both end parts of the main body part, wherein at least one of the flange parts provided at the both end parts is an assembly flange part assembled after the coil is arranged, so that when the coil is arranged between the two flange parts, the assembly flange part is assembled at a prescribed position at the end part of the main body part after the main body part of the main body part passes through the hollow part of the coil. Therefore, the fitting of the fitting flange portion can be performed in a state that can be observed from the outside, and the fitting work can be performed easily and reliably.

Further, if the mounting flange portion includes an engagement portion engaged with the main portion, and the other end portion of the main portion includes an engagement receiving portion for engaging with the engagement portion, and the engagement portion and the engagement receiving portion are engaged by selecting engagement positions of each other, the interval between the flange portions and the mounting flange portion can be adjusted, and the arrangement space of the coil can be adjusted according to the size of the coil. Therefore, it is possible to suppress a problem that the distance between the flange portions is narrow, and the coil cannot be arranged, or a problem that an excessive load is applied to the flange portions, and a problem that the distance between the flange portions is wide, and the coil shakes, can be suppressed. Therefore, the fitting flange portion can be restrained from being unintentionally shifted or dropped.

Further, if a plurality of engagement portions are formed so that at least one of the engagement portions and the engagement receiving portions are different in position in the axial direction of the trunk portion, the engagement positions of the engagement portions and the engagement receiving portions can be easily selected, and the positioning of the fitting flange portion can be performed promptly.

Further, if the engagement receiving portion is provided on the outer peripheral surface of the main body portion, a portion where the engagement portion of the fitting flange portion is engaged can be easily visually confirmed during the fitting operation of the fitting flange portion. Therefore, the assembly work is easily performed without stagnation, and the work efficiency can be improved.

Further, if the engaging portion is provided with an engaging limiting portion capable of maintaining an engaged state of the engaging portion and the engaging receiving portion, the fitting flange portion can be further prevented from being displaced or detached.

Further, since the flange portions attached to at least one end portion of each trunk portion are restrained from moving in the lateral direction by the other trunk portion, the removal prevention of the assembled flange portions can be achieved in the manufactured reactor.

Further, by providing the plurality of trunk portions arranged in parallel and integrating at least one of the fitting flange portion fitted to one end portion of each trunk portion and the fitting flange portion fitted to the other end portion of each trunk portion, the number of structural members of the reactor frame can be reduced, and the flange fitting work to the plurality of trunk portions can be performed at a time, thereby improving the manufacturing efficiency.

In the reactor frame and the reactor according to the second aspect of the present invention, the effects of the reactor frame and the reactor according to the present invention can be obtained, and the fitting positions of the fitting flange portions can be adjusted to predetermined positions according to the coil lengths, so that the relative positions of the coils with respect to the trunk portion can be set to a desired state, and the degree of freedom in designing the reactor can be increased.

Further, by adjusting the fitting positions of the fitting flange portions at the both end portions to dispose the center position of the coil at the set position in design, desired magnetic characteristics can be ensured.

In addition, a method of manufacturing a first reactor according to the present invention includes: a skeleton forming step of forming a skeleton main body portion having a fixing flange portion at one end of the main body portion, and an attachment flange portion attached to the other end of the main body portion; a coil forming step of winding an electric wire to form a coil; a coil mounting step of passing the trunk portion through an air core portion of the coil to mount the coil around the trunk portion; a flange portion assembling step of assembling the assembly flange portion to the trunk portion to which the coil is attached; and a core assembly step of assembling the magnetic core so as to house the leg portions of the magnetic core in the hollow portion of the main portion provided with the coil and the fitting flange portion, whereby the reactor can be assembled without any trouble using the reactor frame provided with the fitting flange portion and the coil, and the assembling work of the reactor can be facilitated.

On the other hand, the manufacturing method of the second reactor according to the present invention includes: a skeleton forming step of forming a trunk portion and fitting flange portions fitted to both end portions of the trunk portion, respectively; a coil forming step of winding an electric wire to form a coil; a first flange portion assembling step of assembling one of the flange portions at a predetermined position of one end portion of the main portion; a coil mounting step of passing the trunk portion, to which the fitting flange portion is fitted at one end, through a hollow portion of the coil to mount the coil around the trunk portion; a second flange portion fitting step of fitting the other fitting flange portion to a predetermined position of the other end portion of the trunk portion to which the coil is attached; and a core assembly step of assembling the magnetic core so as to house the leg portions of the magnetic core in the hollow portion of the main portion provided with the coil and the fitting flange portion, whereby the reactor can be assembled without any trouble using the reactor frame provided with the fitting flange portion and the coil, and the assembling work of the reactor can be facilitated.

Drawings

Fig. 1 is a perspective view of a reactor including a first group of a reactor skeleton according to a first embodiment of the present invention.

Fig. 2 is an exploded perspective view of the reactor of fig. 1.

Fig. 3 is a perspective view of the reactor frame of fig. 1, (a) showing a state in which the fitting flange portion is fitted to the frame body portion, and (b) showing a state in which the fitting flange portion is detached from the frame body portion.

Fig. 4 is an explanatory view of an assembling process of the reactor of fig. 1, (a) is an explanatory view of a coil mounting process, (b) is an explanatory view of a flange portion assembling process, and (c) is an explanatory view of a core assembling process.

Fig. 5 is an explanatory view of a reactor frame including a pair of trunk portions in a frame main body portion according to a second embodiment of the first group of the present invention, (a) is a perspective view of a configuration in which fitting flange portions are fitted to the trunk portions, respectively, and (b) is a perspective view of a configuration in which a single fitting flange portion is bridged to the pair of trunk portions.

Fig. 6 is a perspective view of a reactor frame including three trunk portions in a frame body portion according to a third embodiment of the first group of the present invention.

Fig. 7 is an explanatory view of a reactor frame including an engagement receiving portion formed of grooves having a V-shaped cross section and an engagement portion formed of projecting strips having a sharp cross section according to a fourth embodiment of the first group of the present invention, (a) is a perspective view, and (b) is a cross-sectional view in an engaged state of the engagement portion and the engagement receiving portion.

Fig. 8 is an explanatory view of a reactor frame including an engagement stopper portion including a concave portion and a convex portion according to a fifth embodiment of the first group of the present invention, (a) is a perspective view, and (b) is a cross-sectional view.

Fig. 9 is a perspective view of a reactor including a reactor skeleton according to a first embodiment of a second group of the present invention.

Fig. 10 is an exploded perspective view of the reactor of fig. 9.

Fig. 11 is a perspective view of the reactor frame of fig. 9, (a) showing a state in which the fitting flange portion is fitted to the trunk portion, and (b) showing a state in which the fitting flange portion is detached from the trunk portion.

Fig. 12 is an explanatory view of an assembling process of the reactor of fig. 9, (a) is an explanatory view of a first flange portion assembling process, (b) is an explanatory view of a coil mounting process, (c) is an explanatory view of a second flange portion assembling process, and (d) is an explanatory view of a core assembling process.

Fig. 13 is an explanatory view of a reactor frame including a pair of trunk portions according to a second embodiment of the present invention, (a) is a perspective view of a configuration in which a single fitting flange portion is provided between one end portions of the trunk portions, and separate fitting flange portions are respectively fitted to the other end portions of the trunk portions, and (b) is a perspective view of a configuration in which a single fitting flange portion is provided between both end portions of the trunk portions.

Fig. 14 is a perspective view of a reactor skeleton including three parallel trunk portions according to a third embodiment of the second group of the present invention.

Fig. 15 is an explanatory view of a reactor frame including an engagement receiving portion including a groove having a V-shaped cross section and an engagement portion including a ridge having a sharp cross section according to a fourth embodiment of the second group of the present invention, (a) is a perspective view, and (b) is a cross-sectional view of the engagement portion and the engagement receiving portion in an engaged state

Fig. 16 is an explanatory view of one end portion of a reactor frame including an engagement stopper portion formed of a concave portion and a convex portion according to a fifth embodiment of the second group of the present invention, (a) is a perspective view, and (b) is a cross-sectional view.

Description of the reference numerals

100. 2100: A reactor; 110. 2110: a coil; 111. 2111: a hollow core portion; 120. 220, 320, 420, 520, 2120, 2220, 2320, 2420, 2520: a skeleton for a reactor; 121. 221, 321, 421, 521: a skeleton main body; 121A, 221A, 321A, 421A, 521A, 2121, 2221, 2321, 2421, 2521: a main body; 121B, 221B, 321B, 421B: a fixing flange portion; 121C, 221C, 321C, 421C, 521C, 2121C, 2221C, 2321C, 2421C, 2521C: a clamping receiving part; 122. 222, 223, 323, 422, 522, 2122, 2222, 2223, 2323, 2422, 2522: assembling the flange part; 1221. 3221: a first sheet; 1222. 3222: a second sheet; 1223. 3223: a third sheet; 122A, 223A, 323A, 422A, 2122A, 2223A, 2323A, 2422A: a fitting hollow portion; 122B, 223B, 323B, 2122B, 2223B, 2323B: a fitting inlet; 122C, 222C, 223C, 323C, 422C, 522C, 2122C, 2222C, 2223C, 2323C, 2422C, 2522C: an engagement portion; 122D, 222D, 223D, 323D, 2122D, 2222D, 2223D, 2323D: a clamping limit part; 130. 2130: a magnetic core; 131. 2131: core block; 132. 2132: a leg portion; 521E, 2521E: a concave portion; 522E, 2522E: a convex part.

Detailed Description

< First group >

The coil component of the reactor including the reactor frame according to the first embodiment of the first group of the present invention will be described below with reference to fig. 1 to 4.

The reactor 100 is used as a circuit element of a solar power generation device, a wind power generation device, a charging device for an electric vehicle, or the like, and is configured to include, as shown in fig. 1: a pair of coils 110 arranged in parallel; a pair of cylindrical reactor bobbins 120 to which the coils 110 are attached; and an annular magnetic core 130, a part of which passes through the hollow portion of each reactor skeleton 120. The reactor frame 120 is made of an insulator such as a resin, and insulates the coil 110 from the magnetic core 130. In the present application, when the term "reactor frame" is used, if any of the structural members is integrated, for example, if flange portions (fixed flange portions 121B and the like described below) formed at one ends of two trunk portions (121A and the like described below) are integrated with each other, the term "reactor frame" is also indicated as a single piece as a whole.

The coil 110 is a flat coil formed by rolling up one flat wire (electric wire) into a square tube shape, and a hollow portion 111 penetrating along the longitudinal direction (winding axis direction) of the coil 110 is provided inside, and a bobbin main body portion 121 of the reactor bobbin 120 can be inserted into the hollow portion 111. The magnetic core 130 is formed in a ring shape by connecting a pair of U-shaped core blocks 131 in a symmetrical posture, and the leg portions 132 located at both end portions of the yoke portion of each core block 131 can be inserted into the trunk portion 121A of the bobbin 120, respectively (see fig. 1 and 2).

Next, the reactor frame 120 will be described.

As shown in fig. 3, the reactor frame 120 includes a frame body 121 and a fitting flange 122 fitted to the frame body 121. The frame body 121 includes a hollow rectangular tubular trunk portion 121A, and the coil 110 can be disposed around the trunk portion 121A in a wound state, and a fixing flange portion 121B extending over the entire circumference of the trunk portion 121A is provided at one end portion of the trunk portion 121A so as to extend outward, and the posture of the fixing flange portion 121B is set to a state extending in a direction orthogonal to the axial direction of the trunk portion 121A. The hollow portion of the trunk 121A is formed so as to penetrate along the axial direction of the trunk 121A, and the leg portions 132 of the pair of core pieces 131 (the magnetic cores 130) can be accommodated (inserted) into the hollow portion from both end portions of the trunk 121A.

The fitting flange 122 is a thin-walled plate-shaped flange member fitted to the other end portion of the trunk 121A, and has a substantially C-frame shape that is one turn larger than the rectangular cross section of the trunk 121A, and more specifically, has a shape in which the second piece 1222 and the third piece 1223 extend upward and downward from the upper end and the lower end of the first piece 1221 that are long in the longitudinal direction in the figure in the same lateral direction orthogonal to the first piece 1221. Further, a fitting hollow 122A is provided at a central portion surrounded by the first sheet 1221, the second sheet 1222, and the third sheet 1223, and an open portion (between the front end of the second sheet 1222 and the front end of the third sheet 1223) in an outer peripheral portion formed by the continuous first sheet 1221 to third sheet 1223 is communicated with the fitting hollow 122A as a fitting inlet 122B, and the trunk portion 121A of the skeleton 120 is configured to be fitted into the fitting hollow 122A through the fitting inlet 122B (see fig. 3 (B)). The opening edge portion of the fitting hollow portion 122A (the inner edge portion of the fitting flange portion 122 formed by the inner edges of the first to third pieces 1221 to 1223) is used as the engaging portion 122C, and the engaging portion 122C is configured to engage with the trunk portion 121A side (specifically, the outer peripheral surface of the trunk portion 121A) when the trunk portion 121A is fitted into the fitting hollow portion 122A.

An engagement receiving portion 121C for engaging with the engagement portion 122C is provided on the outer peripheral surface of the other end portion (the other end portion to which the fitting flange portion 122 is fitted) of the trunk portion 121A. Specifically, in the case where the engagement receiving portion 121C formed of a groove having a rectangular cross section is extended in the circumferential direction (direction orthogonal to the axial direction) of the trunk portion 121A, the engagement receiving portion 121C is set to be parallel to the fixing flange portion 121B. The engagement receiving portions 121C are formed in such a manner that they are arranged at equal intervals in the axial direction of the trunk portion 121A, and the distance separating each engagement receiving portion 121C from the fixing flange portion 121B is different. In the present embodiment, the groove-shaped engagement receiving portion 121C is not formed in a part of the corner portion rounded in the outer peripheral surface of the other end portion of the trunk portion 121A, but the engagement receiving portion 121C may be continuously formed over the entire outer peripheral surface of the other end portion of the trunk portion 121A.

The reactor frame 120 includes an engagement stopper 122D that can maintain an engaged state between the engagement portion 122C and the engagement receiving portion 121C. As shown in fig. 3B, the engagement stopper 122D is configured by providing a pair of protrusions protruding toward the fitting inlet 122B on both sides of the fitting inlet 122B, and is set to have the same plate thickness dimension as the fitting flange 122, and is further set to have the same plate thickness dimension as the engagement portion 122C (inner edge portion of the fitting flange 122).

In the arrangement in which the pair of bobbins 120 shown in fig. 1 and 2 are arranged adjacently in parallel, the fixing flange portions 121B are fixedly arranged at one end portions of the respective trunk portions 121A, and the coil 100 is assembled from the other end portions of the trunk portions 121A. Thereafter, the fitting flange portions 122 are respectively attached to the other end portions of the trunk portion 121A protruding from the coil 100, but the fitting direction is configured to be fitted from the adjacent side. That is, as shown in fig. 2, when the fitting flange portions 122 are attached to the two trunk portions 121A from the lateral directions on opposite sides and are assembled with the leg portions 132 of the magnetic core 130, the back portions of the first pieces 1221 in the longitudinal directions of the fitting flange portions 122 are disposed adjacent to the bobbins 120 (see fig. 1). Thus, in the manufactured reactor 100, the assembled fitting flange portion 122 cannot be detached.

Next, a method of manufacturing the reactor 100 will be described.

In the production of the reactor 100, a step of forming each structural member of the reactor 100 and a step of assembling the reactor 100 using each structural member are performed. In the step of forming the structural members of the reactor 100, the skeleton main body 121 and the fitting flange 122 are formed separately by injection molding or the like (skeleton forming step), a flat wire (electric wire) is edgewise wound to form the coil 110 (coil forming step), and a U-shaped core block 131 is formed by performing powder molding, cutting a metal block, laminating a metal plate, or the like (core block forming step).

After each structural member of the reactor 100 is formed, the assembly process of the reactor 100 is performed using the pair of skeleton main portions 121, the pair of assembly flange portions 122, the pair of coils 110, and the pair of pellets 131. First, as shown in fig. 4 (a), for each coil 110, a stem 121A of a skeleton body 121 is passed through a hollow portion 111 from the other end portion (the other end portion in a state where the fitting flange 122 is not fitted) of the stem 121A, and the coil 110 is fitted around the stem 121A, that is, a coil fitting portion (coil fitting step). Then, one end portion of the coil 110 is brought into contact with the fixing flange portion 121B, and the other end portion of the trunk portion 121A is projected from the other end portion of the coil 110 so that the engagement receiving portion 121C is exposed to the outside.

After the coil 110 is attached to the bobbin main body 121, the flange 122 is attached to the other end portion (the end portion including the engagement receiving portion 121C) of each trunk 121A (flange attaching step). Specifically, as shown in fig. 4 (B), the fitting flange 122 is set to a posture in which the fitting inlet 122B faces the trunk 121A and a posture in which the fitting flange 122B is parallel to the fixing flange 121B with respect to the frame body 121, and the fitting flange 122 is deflected to widen the fitting inlet 122B. Then, if the interval between the engagement limiting portions 122D is widened to a state where the trunk portion 121A can be fitted, the fitting inlet 122B is brought close to the trunk portion 121A in this state, and the fitting flange portion 122 is fitted to the other end portion of the trunk portion 121A. At this time, among the plurality of engagement receiving portions 121C, an engagement receiving portion 121C that can be engaged by the engagement portion 122C at a position where the fitting flange portion 122 abuts against the other end portion of the coil 110 or a position closest to the other end portion of the coil 110 is selected, and the engagement portion 122C is brought close to the selected engagement receiving portion 121C.

Then, when the stem portion 121A is disposed in the fitting hollow portion 122A so that the fitting flange portion 122 is sufficiently fitted into the stem portion 121A, the engagement limiting portion 122D passes over and is separated from the outer peripheral surface of the stem portion 121A, whereby the deflection of the fitting flange portion 122 is released, the engagement portion 122C engages with the engagement receiving portion 121C, and the engagement limiting portion 122D is hooked on the corner portion of the stem portion 121A. As a result, the coil 110 is wound around each trunk 121A of the pair of reactor bobbins 120, and the engagement portions 122C and the engagement receiving portions 121C are engaged by selecting the engagement positions of each other, so that the interval between the fixing flange portions 121B and the fitting flange portions 122 is adjusted in accordance with the actual size of the coil 110.

After the coil 110 is mounted on the reactor frame 120, the leg portions 132 of the pair of magnetic cores 130 are inserted into the hollow portion of the trunk portion 121A from both sides (core assembly step). Specifically, as shown in fig. 4 (c), the pair of reactor bobbins 120 to which the coils 110 are attached are arranged in a direction orthogonal to the axial direction of the trunk 121A, one leg 132 of the U-shaped core block 131 is inserted into one end of the hollow portion of each trunk 121A, and the other leg 132 of the U-shaped core block 131 is inserted into the other end of the hollow portion of the trunk 121A. If the distal ends of the leg portions 132 are joined to each other using an adhesive or the like in the hollow portion of the trunk portion 121A, the annular magnetic core 130 is formed, and a part of the magnetic core 130 is housed in the hollow portion of the trunk portion 121A (the reactor frame 120).

Then, by applying a liquid insulating material such as varnish to the surface of each coil 110, the insulating material is immersed in a gap between the flat wires or is further filled between the coil (flat wires) 110 and the reactor frame 120 (the trunk portion 121A, the fixing flange portion 121B, and the fitting flange portion 122). Then, the insulating material is cured to perform an insulating treatment (surface treatment) of the coil 110, thereby completing the reactor 100. At this time, when the insulating material is cured, the coil 110 and the reactor bobbin 120 are fixed by the intervention of the insulating material. The insulation treatment of the coil 110 may be performed between the flange portion assembling step and the core assembling step.

In this way, if the reactor frame 120 is configured by attaching the attachment flange 122 to the frame body 121 and the reactor frame 120 is used as a component of the reactor 100, the space length (the distance between the flange 121B and 122) for the coil 110 to be wound can be adjusted according to the size of the coil 110. Therefore, it is possible to suppress a problem that the coil 110 cannot be arranged or the coil 110 is biased to be provided because the distance between the fixing flange portion 121B and the mounting flange portion 122 is narrow, and an excessive load is applied to both flange portions 121B and 122, or a problem that the coil 110 can be provided in the opposite direction but the distance between both flange portions 121B and 122 is wider than the coil length, and rattling occurs. Further, even if the fixation of the coil 110 to the trunk 121A by an insulating material such as varnish is released by an external force such as vibration of the coil 110, the dimensional difference can be reduced, and the coil 110 can be prevented from largely shaking by the two flange portions 121B and 122.

Further, the plurality of engagement receiving portions 121C are formed in a state different from the position of the fixing flange portion 121B, and by selecting any one of the engagement receiving portions 121C and engaging the engagement portion 122C (in other words, the engagement portion 122C and the engagement receiving portion 121C are engaged by selecting the engagement position of each other), the interval between the fixing flange portion 121B and the fitting flange portion 122 can be adjusted, so that the fitting flange portion 122 can be prevented from being unintentionally shifted or detached. Further, the engagement position of the engagement portion 122C and the engagement receiving portion 121C can be easily selected, and the positioning of the fitting flange portion 122 can be performed quickly.

Further, since the engagement receiving portions 121C are provided on the outer peripheral surface of the trunk portion 121A, the portion where the engagement portions 122C of the fitting flange portion 122 are engaged can be easily visually confirmed in the fitting operation (flange portion fitting step) of the fitting flange portion 122. Therefore, the assembly work is easily and reliably performed without stagnation, and the work efficiency can be improved. Further, since the engagement limiting portion 122D is provided, which can maintain the engaged state of the engaging portion 122C and the engaging receiving portion 121C, the fitting flange portion 122 can be further prevented from being displaced or coming off. Further, since the reactor 100 is manufactured by the manufacturing method including the above-described steps (skeleton forming step, coil mounting step, flange portion assembling step, and core assembling step), the reactor 100 can be assembled without any trouble using the reactor skeleton 120 provided with the assembly flange portion 122 and the coil 110, and thus the assembling work of the reactor 100 can be facilitated.

The reactor frame 120 in the first embodiment of the first group is configured such that the fixing flange portion 121B is provided at one end of the trunk portion 121A of each of the frame body portions 121 of the pair of frames 120 disposed adjacently, but the present invention is not limited thereto. For example, the reactor skeleton 220 of the second embodiment shown in fig. 5 is substantially the same as the first embodiment of the first group, but differs in the following respects: the fixing flange 221B fixed to one end of the pair of trunk parts 221A provided in parallel to the frame body 221, and the fitting flange 223 fitted to the other end are integrally connected.

Specifically, the backbone main body 221 of the reactor backbone 220 in the first group of the second embodiment shown in fig. 5 (a) and (B) includes a pair of trunk portions 221A arranged in parallel, and the fixing flange portions 221B arranged at one end of each trunk portion 221A are integrally and continuously formed, so that one end of the pair of trunk portions 221A of the backbone 220 is connected to each other by the fixing flange portions 221B. The other end portion of each trunk portion 221A is provided with engagement receiving portions 221C formed of grooves, a plurality of (four in the present embodiment) engagement receiving portions 221C are arranged at equal intervals along the axial direction of the trunk portion 221A, and the distance separating each engagement receiving portion 221C from the fixing flange portion 221B is set to be different depending on the engagement receiving portion 221C. In this aspect, the number of structural members can be reduced, and thus improvement in manufacturing efficiency can be achieved.

In the embodiment shown in fig. 5 (a), a separate C-shaped fitting flange 222 is fitted to each trunk 221A from above, and the engagement receiving portion 221C is engaged with the engagement portion 222C, so that the engagement state can be maintained by the engagement limiting portion 222D. Alternatively, in the embodiment shown in fig. 5 (b), the fitting flange portion 223 provided at the other end portion of each trunk portion 221A of the skeleton main body portion 221 is also integrated. The integrated fitting flange portion 223 is configured by providing a pair of fitting hollow portions 223A and a pair of fitting inlets 223B in a rectangular flat plate in a laterally aligned state, fitting the fitting flange portion 223 between the other end portions of the trunk portion 221A in a stretched state, and engaging the engaging receiving portion 221C with the engaging portion 223C, whereby the engaging state can be maintained by the engaging limiting portion 223D.

If a separate fitting flange portion 222 is fitted to the trunk portion 221A of fig. 5 (a), even if the coils are designed to have different numbers of turns (windings) from each other, even if the coils are designed to have different length dimensions, the fitting portions of the fitting flange portions 222 can be adjusted to match the length dimensions of the coils. On the other hand, if the fitting flange portion 223 of fig. 5 (b) is provided so as to be interposed between the trunk portions 221A, the number of structural members of the reactor can be reduced. In addition, the flange assembly work on the pair of trunk portions 221A can be performed at a time, and thus the manufacturing efficiency can be improved.

The third embodiment of the first group shown in fig. 6 shows a reactor skeleton 320 corresponding to three-phase ac, and is provided with three coils, similar to the manner of fig. 5 (b) as a whole. The backbone main body 321 of the reactor backbone 320 of this embodiment is configured such that three trunk portions 321A are arranged in a parallel state (a state of being aligned in a direction orthogonal to the axial direction of each trunk portion 321A), and one end portion of each trunk portion 321A is connected by an integrally formed fixing flange portion 321B.

In fig. 6, an integrated fitting flange portion 323 is attached to the other end portion of each trunk portion 321A, and the fitting flange portion 323 is formed in a flat plate shape in which three fitting hollow portions 323A and three fitting inlets 323B are opened in a laterally aligned state. The fitting flange 323 is fitted to each trunk 321A in a stretched state, and the engagement receiving portion 321C is engaged with the engagement portion 323C, so that the engagement state can be maintained by the engagement limiting portion 323D. As in the case of fig. 5 (a), a separate fitting flange portion (not shown) may be attached to each trunk portion 321A.

In the above-described first group of embodiments, the groove-shaped engagement receiving portions 121C, 221C, 321C are formed on the four surfaces of the outer peripheral surfaces of the rectangular tubular trunk portions 121A, 221A, 321A, but the present invention is not limited thereto. The range of forming the engagement receiving portion is not limited as long as the engagement portion can be engaged with the outer peripheral surface of the trunk portion. For example, a groove-shaped engagement receiving portion may be formed by selecting one or more of three surfaces of the outer peripheral surface of the rectangular cylindrical main portion, which can be opposed to the inner edge portion (engagement portion) of the fitting flange portion, or may be formed at a corner portion of the outer peripheral surface of the main portion. In addition, when the fitting flange portion is formed in an arc shape, the cylindrical main portion may be formed by forming a groove-shaped engagement receiving portion in a portion of the outer peripheral surface of the main portion that can face the inner edge portion (engagement portion) of the fitting flange portion, and the engagement receiving portion does not need to be formed over the entire outer peripheral surface of the main portion.

In the first group of embodiments, the engagement receiving portions 121C, 221C, 321C are formed of grooves having rectangular cross sections, and the cross sections of the engagement portions 122C, 222C, 223C, 323C are rectangular, but the present invention is not limited thereto. The key is that the engagement portion and the engagement receiving portion are not limited as long as they can engage with each other.

For example, as shown in the fourth embodiment of the first group in fig. 7, in the reactor frame 420, the engagement receiving portion 421C may be formed of a groove having a V-shaped cross section and provided in the trunk portion 421A of the frame body portion 421, and the engagement portion 422C may be formed of a ridge having a sharp cross section and provided in the opening edge portion of the fitting hollow portion 422A of the fitting flange portion 422. If the engagement receiving portions 421C are formed of grooves having a V-shaped cross section, the distance between the engagement receiving portions 421C can be easily set narrower than that of grooves having a rectangular cross section, so that the selectivity of the mounting position of the mounting flange portion 422 is improved, and the adjustability of the distance between the fixing flange portion 421B and the mounting flange portion 422 is improved.

In the first group of embodiments, the plurality of engagement receiving portions 121C, 221C, 321C provided in the trunk portions 121A, 221A, 321A are formed as grooves, and the engagement portions 122C, 222C, 223C, 323C provided in the fitting flange portions 122, 222, 223, 323 are formed as protrusions, but the present invention is not limited thereto. The key is that any combination of the engaging portion and the engaging receiving portion may be employed as long as the structure is such that the interval between the fixing flange portion and the fitting flange portion can be adjusted by selecting and engaging the engaging positions with each other. For example, the engagement receiving portions provided on the outer peripheral surface of the other end portion of the trunk portion may be formed by protrusions or pin-shaped projections, and the engagement portions provided on the opening edge portion of the fitting hollow portion of the flange portion may be formed by grooves.

In the first group of embodiments, the engagement receiving portions 121C, 221C, 321C provided in the trunk portions 121A, 221A, 321A are formed in plural numbers so as to be different in position (separation distance) from the fixing flange portions 121B, 221B, 321B, but the present invention is not limited thereto. The engagement portion and the engagement receiving portion are not limited as long as at least one of them is formed in plural at different positions from the fixing flange portion. For example, the opening edge portion of the fitting hollow portion of the fitting flange portion may be expanded in the plate thickness direction (axial direction of the trunk portion) of the fitting flange portion, and the expanded edge portion may be provided with a plurality of groove-shaped engagement receiving portions that are offset in the plate thickness direction (axial direction of the trunk portion) of the fitting flange portion. The engaging portion on the trunk portion to which the engaging receiving portion is engaged may be constituted by a single projecting strip, or a plurality of projecting strips may be arranged so as to be offset in the axial direction of the trunk portion so as to match the pitch of the plurality of engaging receiving portions. However, if the engaging portion on the trunk portion is formed of a bead, a protrusion, or the like and protrudes from the outer peripheral surface of the trunk portion, there is a risk that the engaging portion (bead, protrusion, or the like) is caught on the inner peripheral surface of the coil in the coil mounting step, and the assembly operation is stopped. In contrast, if the engaging portion on the trunk portion is configured not to protrude from the outer peripheral surface of the trunk portion (such as a groove or recess formed by recessing the outer peripheral surface), it is preferable that the trunk portion is difficult to be caught by the inner peripheral surface of the coil in the coil mounting step, and the assembling work of the reactor is easy to be performed without stagnation.

In the first group of embodiments, the engagement limiting portions 122D, 222D, 223D, 323D having the protruding structure are exemplified as the engagement limiting portions of the present invention, but the present invention is not limited thereto. The key is that the engagement limiting portion may be any structure as long as the engagement state between the engagement portion and the engagement receiving portion can be maintained.

For example, as shown in the fifth embodiment of the first group of fig. 8, in the reactor frame 520, an engagement restriction portion may be constituted by a concave portion 521E formed in the outer peripheral surface of the trunk portion 521A of the frame main body portion 521 and a convex portion 522E provided so as to protrude from the fitting flange portion 522, and the engagement state of the engagement receiving portion 521C and the engagement portion 522C (the fitting state of the fitting flange portion 522) may be maintained by engagement of the concave portion 521E and the convex portion 522E. Alternatively, a rectangular member (not shown) capable of closing the fitting entrance of the fitting flange portion may be used as the engagement stopper portion, and the fitting entrance of the fitting flange portion fitted to the trunk portion may be closed by the engagement stopper portion (rectangular member) to maintain the engagement state of the engagement portion and the engagement receiving portion, thereby preventing the fitting flange portion from coming off the trunk portion.

In the first group of embodiments, the assembly flange portions 122, 222, 223, 323 are constituted by a single member having a substantially C-shape or a substantially E-shape, but the present invention is not limited thereto. The key is that the fitting flange portion may have any structure as long as it can be fitted to the other end portion of the trunk portion. For example, the two substantially C-shaped frame members may be opposed to each other to form a rectangular frame-shaped fitting flange portion, and the fitting flange portion may be fitted to the trunk portion by sandwiching the trunk portion between the two frame members in the flange fitting step and engaging the end portions of the frame members with each other in this state.

The coil 110 described in each of the first group of embodiments is formed by winding a flat wire in an edgewise manner, but the present invention is not limited thereto. The configuration is not limited as long as the coil is formed by winding an electric wire. For example, a coil formed by winding a round wire (wire having a circular cross section) may be applied to the reactor and the method for manufacturing the reactor of the present invention.

< Second group >

The coil portion including the reactor frame according to the first embodiment of the second group of the present invention will be described below with reference to fig. 9 to 12.

The reactor 2100 is used as a circuit element of a solar power generation device, a wind power generation device, a charging device for an electric vehicle, or the like, and is configured to include, as shown in fig. 9: a pair of coils 2110 arranged in parallel; a pair of cylindrical reactor bobbins 2120 to which the coils 2110 are attached; and an annular magnetic core 2130, a part of which passes through the hollow portion of each reactor frame 2120. The reactor frame 2120 is made of an insulator such as a resin, and insulates the coil 2110 from the magnetic core 2130. In the present application, when the term "reactor skeleton" is used, if any of the structural members is integrated, for example, if the flange portions (fitting flange portions 2122) formed at one ends of the two trunk portions (hereinafter, 2121 and the like) are integrated with each other, the term "reactor skeleton" is also indicated as a single member as a whole.

The coil 2110 is a flat coil formed by rolling up a single flat wire (electric wire) into a square tube shape, and a hollow portion 2111 penetrating along the longitudinal direction (winding axis direction) of the coil 2110 is provided inside, and a trunk portion 2121 of the reactor frame 2120 can be inserted into the hollow portion 2111. The magnetic core 2130 is formed in a ring shape by connecting a pair of U-shaped core blocks 2131 in a symmetrical posture, and leg portions 2132 of each core block 2131 located at both end portions of the yoke portion can be inserted into the trunk portion 2121 of the frame 2120 (see fig. 9 and 10).

Next, the reactor frame 2120 will be described.

As shown in fig. 11, the reactor frame 2120 includes: a trunk 2121 having a hollow rectangular tubular shape; a pair of fitting flange portions 2122, which are fitted to both end portions of the trunk portion 2121, respectively. The coil 2110 can be disposed around the stem 2121 in a wound state, and the coil 2110 can be inserted into (or inserted into) the hollow portion of the stem 2121 along the axial direction of the stem 2121, and the pair of leg portions 2132 of the core block 2131 (the magnetic core 2130) can be accommodated in (or inserted into) the hollow portion from both end portions of the stem 2121.

The fitting flange 2122 is a thin plate-shaped flange member fitted to both ends of the one end portion and the other end portion of the stem 2121, and has a substantially C-frame shape that is one turn larger than the rectangular cross section of the stem 2121, and more specifically, is a shape in which the second piece 3222 and the third piece 3223 extend from the upper end and the lower end of the first piece 3221, which are long in the longitudinal direction in the drawing, in the same lateral direction orthogonal to the first piece 3221, up and down. A fitting hollow 2122A is provided at a central portion surrounded by the first piece 3221, the second piece 3222, and the third piece 3223, and an open portion (between the distal end of the second piece 3222 and the distal end of the third piece 3223) in an outer peripheral portion formed by the continuous first piece 3221 to third piece 3223 is communicated with the fitting hollow 2122A as a fitting inlet 2122B, and the trunk portion 2121 formed as the skeleton 2120 is fitted into the fitting hollow 2122A through the fitting inlet 2122B (see fig. 11 (B)). The opening edge portion of the fitting hollow portion 2122A (the inner edge portion of the fitting flange portion 2122 constituted by the inner edges of the first to third pieces 3221 to 3223) is defined as an engagement portion 2122C, and the engagement portion 2122C is engaged with the stem portion 2121 side (specifically, the outer peripheral surface of the stem portion 2121) when the stem portion 2121 is fitted into the fitting hollow portion 2122A. In a state of being attached to the stem 2121, the stem 2121 is set to have a posture extending in a direction orthogonal to the axial direction of the stem 2121.

The outer peripheral surfaces of both end portions of the trunk portion 2121 (both end portions to which the fitting flange portions 2122 are respectively attached) are provided with engagement receiving portions 2121C to which the engagement portions 2122C are engaged, respectively. Specifically, the engagement receiving portions 2121C formed of grooves having rectangular cross sections are formed so as to extend in the circumferential direction (direction orthogonal to the axial direction) of the trunk portion 2121, and a plurality of (four in the present embodiment) engagement receiving portions 2121C are arranged so as to be offset in the axial direction of the trunk portion 2121 at equal intervals. In the present embodiment, the engagement receiver 2121C having a groove shape is not formed in a part of the rounded corner portion of the outer peripheral surface of the trunk portion 2121, but the engagement receiver 2121C may be continuously formed over the entire outer peripheral surface of the trunk portion 2121.

The reactor frame 2120 includes an engagement stopper 2122D that can maintain an engagement state between the engagement portion 2122C and the engagement receiver 2121C. As shown in fig. 11 (B), the engagement limiting portion 2122D is configured by providing a pair of protrusions protruding toward the fitting inlet 2122B side on both sides of the fitting inlet 2122B, and is set to the same plate thickness dimension as the fitting flange portion 2122, and is further set to the same plate thickness dimension as the engagement portion 2122C (inner edge portion of the fitting flange portion 2122).

In the case where the pair of bobbins 2120 shown in fig. 9 and 10 are arranged adjacently in parallel, first, the fitting flange portions 2122 are fitted at predetermined positions on one end portions of the respective trunk portions 2121, and the coil 2100 is fitted from the other end portions of the trunk portions 2121. Thereafter, the other fitting flange portions 2122 are respectively attached to the other end portions of the trunk portion 2121 protruding from the coil 2100, but the fitting direction thereof is configured to be fitted from the adjacent side. That is, as shown in fig. 10, when the other fitting flange portions 2122 are attached to both end portions of the two trunk portions 2121 from the lateral directions opposite to each other and then assembled with the leg portions 2132 of the magnetic core 2130, the back portions of the first pieces 3221 in the longitudinal directions of the fitting flange portions 2122 are fitted to the adjacent skeletons 2120 so as to be close to each other (see fig. 9). Thus, in the manufactured reactor 2100, the assembled fitting flange portion 2122 cannot be detached.

Next, a method of manufacturing the reactor 2100 will be described.

In the manufacturing of the reactor 2100, a step of forming each structural member of the reactor 2100 and a step of assembling the reactor 2100 using each structural member are performed. In the step of forming the structural members of the reactor 2100, the trunk portion 2121 and the fitting flange portion 2122 of the armature 2120 are formed separately by injection molding or the like (armature forming step), and a flat wire (electric wire) is edgewise wound to form a coil 2110 (coil forming step), and then pressed to form a pellet 2131 by powder molding, cutting a metal block, laminating a metal plate, or the like (pellet forming step).

After each structural member of the reactor 2100 is formed, an assembly process of the reactor 2100 is performed using the pair of trunk portions 2121, the two pairs of fitting flange portions 2122, the pair of coils 2110, and the pair of pellets 2131. First, the fitting flange portions 2122 are fitted to one end portion of each trunk portion 2121, respectively (first flange portion fitting step). Specifically, as shown in fig. 12 (a), the fitting flange 2122 is set to a posture in which the fitting inlet 2122B faces the stem 2121 and an extended posture orthogonal to the axial direction of the stem 2121 with respect to the stem 2121, and the fitting flange 2122 is deflected to widen the fitting inlet 2122B. Then, if the interval between the engagement limiting portions 2122D is widened to a state where the trunk portion 2121 can be fitted, the fitting inlet 2122B is brought close to the trunk portion 2121 in this state, and the fitting flange portion 2122 is fitted to one end portion of the trunk portion 2121. At this time, a predetermined engagement receiver 2121C that engages with an engagement portion 2122C of the fitting flange portion 2122 is selected from a plurality of engagement receivers 2121C at one end of the trunk portion 2121 based on the arrangement dimensions of the coil 2110 in accordance with the design, specification, etc. of the reactor 2100, and the engagement portion 2122C is brought close to the selected engagement receiver 2121C. Then, when the stem 2121 is disposed in the fitting space 2122A so that the fitting flange 2122 is sufficiently fitted into the stem 2121, the engagement stopper 2122D is disengaged from the outer peripheral surface of the stem 2121 by passing over the outer peripheral surface, whereby the fitting flange 2122 is released from the flexure, the engagement portion 2122C engages with the engagement receiver 2121C, and the engagement stopper 2122D is caught at the corner portion of the stem 2121. As a result, the fitting flange portion 2122 is fitted to one end portion of the trunk portion 2121 by selecting the engagement positions of the engagement portions 2122C and the engagement receiving portions 2121C to engage with each other.

Next, as shown in fig. 12 b, for each coil 2110, the stem 2121 is passed through the hollow portion 2111 from the other end portion of the stem 2121 (the other end portion in the state where the flange 2122 is not attached), and the coil 2110 is attached to the periphery of the stem 2121, that is, the coil attachment portion (coil attachment step). One end of the stem 2121 is brought into contact with a side surface of the assembled flange 2122, and the other end of the stem 2121 is projected from the other end of the coil 2110 so that the engagement receiving portion 2121C is exposed to the outside. After the coil 2110 is attached, the attachment flange 2122 may be attached to a predetermined position at one end of the trunk 2121.

After the coil 2110 is attached to the trunk portion 2121, the remaining attachment flange portions 2122 are attached to the other end portions (the end portions including the engagement receiving portions 2121C) of the trunk portions 2121, respectively (second flange portion attaching step). Specifically, as shown in fig. 12 (c), the fitting flange portion 2122 before fitting is set to a posture in which the fitting inlet 2122B faces the stem 2121 and a posture in which the fitting flange portion 2122 after fitting is parallel to the fitting flange portion 2122, and the fitting inlet 2122B is widened by flexing the fitting flange portion 2122 before fitting. Then, if the interval between the engagement limiting portions 2122D is widened to a state where the main portion 2121 can be fitted, the fitting inlet 2122B is brought close to the main portion 2121 in this state, and the fitting flange portion 2122 is fitted to the other end portion of the main portion 2121. At this time, among the plurality of engagement receiving portions 2121C at the other end portion of the trunk portion 2121, an engagement receiving portion 2121C that can be engaged by the engagement portion 2122C at a position where the fitting flange portion 2122 before fitting abuts against the other end portion of the coil 2110 or a position closest to the other end portion of the coil 2110 is selected, and the engagement portion 2122C of the fitting flange portion 2122 before fitting is brought close to the selected engagement receiving portion 2121C. Then, when the stem 2121 is disposed in the fitting space 2122A so that the fitting flange 2122 is sufficiently fitted into the stem 2121, the engagement stopper 2122D is disengaged from the outer peripheral surface of the stem 2121 by passing over the outer peripheral surface, whereby the fitting flange 2122 is released from the flexure, the engagement portion 2122C engages with the engagement receiver 2121C, and the engagement stopper 2122D is caught at the corner portion of the stem 2121. As a result, the coils 2110 are wound around the respective trunk portions 2121 of the pair of reactor bobbins 2120, and the engagement portions 2122C and the engagement receiving portions 2121C are engaged by selecting the engagement positions of each other, so that the interval between the fitting flange portions 2122 is adjusted to match the actual size of the coils 2110.

Next, each leg 2132 of the pair of magnetic cores 2130 is inserted and stored from both sides into the hollow portion of the main portion 2121 on which the coil 2110 is mounted (core assembly step). Specifically, as shown in fig. 12 (d), the pair of reactor bobbins 2120 on which the coils 2110 are mounted are arranged in a direction orthogonal to the axial direction of the trunk 2121, one leg 2132 of the U-shaped core block 2131 is inserted into one end of the hollow portion of each trunk 2121, and the other leg 2132 of the other U-shaped core block 2131 is inserted into the other end of the hollow portion of each trunk 2121. If the distal ends of the leg portions 2132 are joined to each other using an adhesive or the like in the hollow portion of the trunk portion 2121, the annular magnetic core 2130 is formed, and a part of the magnetic core 2130 is housed in the hollow portion of the trunk portion 2121 (the reactor skeleton 2120).

Then, a liquid insulating material such as varnish is applied to the surface of each coil 2110, so that the insulating material is immersed in a gap between the flat wires or further filled between the coil 2110 (flat wires) and the reactor frame 2120 (main body 2121 and fitting flange 2122). Then, the insulating material is cured to perform an insulating treatment (surface treatment) of the coil 2110, thereby completing the reactor 2100. At this time, when the insulating material is cured, the coil 2110 and the reactor frame 2120 are fixed by the insulating material. The insulation treatment of the coil 2110 may be performed between the second flange portion assembling step and the core assembling step.

In this way, if the fitting flange 2122 is fitted to the stem 2121 to form the reactor frame 2120, and the reactor frame 2120 is used as a structural member of the reactor 2100, the space length (distance between the fitting flange 2122) for the coil 2110 to be wound can be adjusted according to the size of the coil 2110. Therefore, it is possible to suppress a problem that the distance between the fitting flange portions 2122 at both ends is narrow, and the coil 2110 cannot be arranged or the coil 2110 is applied, and an excessive load is applied to both flange portions 2122, or a problem that the coil 2110 is applied, but the distance between both fitting flange portions 2122 is wider than the coil length, and rattling occurs. Further, even if the coil 2110 is fixed to the main body 2121 by an insulating material such as varnish and is released by an external force such as vibration of the coil 2110, the difference in size can be reduced, and the coil 2110 can be prevented from being greatly vibrated by the two fitting flange portions 2122.

In addition, since the center position of the coil 2110 can be arranged at a set position in design by adjusting the mounting positions of the two mounting flange portions 2122 as described above, the coil 2110 can be set in a state where the magnetic characteristics of the reactor are good.

Further, by adjusting the mounting positions of the mounting flange portions 2122, the coils 2110 can be arranged in a state aligned with the center of the trunk portion 2121, and the relative positions of the coils 2110 with respect to the trunk portion 2121 can be set at desired design positions, so that the degree of freedom in designing the reactor 2100 can be increased. When the thickness of the coil 2110 wound around the reactor frame 2120 is changed due to a difference in specifications or the like, the fitting flange portions 2122 of an appropriate size (for example, a width that can sufficiently cover the end portions of the coil 2110) may be formed separately from the thickness of the coil 2110 and may be fitted to the both end portions of the trunk portion 2121. Accordingly, the reactor frame 2120 corresponding to the shape change of the coil 2110 can be realized.

Further, a plurality of engagement receiving portions 2121C are formed at one end portion and the other end portion of the trunk portion 2121 so that positions in the axial direction of the trunk portion 2121 are different, and by selecting any one of the engagement receiving portions 2121C to engage the engagement portion 2122C (in other words, the engagement portions 2122C and the engagement receiving portions 2121C are engaged by selecting the engagement positions of each other), the interval between the fitting flange portions 2122 can be adjusted, so that unintentional displacement or detachment of the fitting flange portions 2122 can be suppressed. Further, the engagement position of the engagement portion 2122C and the engagement receiver 2121C can be easily selected, and the fitting flange portion 2122 can be quickly positioned.

Further, since the engagement receiving portions 2121C are provided on the outer peripheral surface of the trunk portion 2121, the portion where the engagement portions 2122C of the fitting flange portion 2122 engage can be easily visually confirmed in the fitting operation (first flange portion fitting step, second flange portion fitting step) of the fitting flange portion 2122. Therefore, the assembly work is easily and reliably performed without stagnation, and the work efficiency can be improved. Further, since the engagement stopper 2122D is provided so as to maintain the engagement state of the engagement portion 2122C and the engagement receiver 2121C, the fitting flange 2122 can be further prevented from being displaced and detached. Further, since the reactor 2100 is manufactured by the manufacturing method including the above-described steps (the skeleton forming step, the coil forming step, the first flange portion assembling step, the coil mounting step, the second flange portion assembling step, and the core assembling step), the reactor 2100 can be assembled without any trouble using the reactor skeleton 2120 provided with the assembling flange portion 2122 and the coil 2110, and the reactor 2100 can be manufactured without stagnation.

The reactor frame 2120 in the first embodiment of the second group includes separate fitting flange portions 2122 at both ends of the pair of trunk portions 2121 disposed adjacently, but the present invention is not limited thereto. For example, the reactor skeleton 2220 of the second embodiment of the second group shown in fig. 13 is substantially the same as the first embodiment of the second group, but differs in the following respects: the fitting flange portions 2222, which are fitted to one end or both ends of the paired trunk portions 2221, are integrally connected.

Specifically, the reactor frame 2220 in the second embodiment of the second group shown in fig. 13 (a) and (b) includes a pair of parallel trunk portions 2221, and engagement receiving portions 2221C formed of grooves are provided at both end portions of each trunk portion 2221, and a plurality of (four in the present embodiment) engagement receiving portions 2221C are arranged at equal intervals along the axial direction of the trunk portion 2221. The integrated fitting flange portion 2222 is configured such that a pair of fitting hollow portions 2222A and a pair of fitting inlets 2222B are formed in a rectangular flat plate in a laterally aligned state, and the trunk portions 2221 are fitted into the respective fitting hollow portions 2222A (in other words, the engagement receiving portions 2221C are engaged with the engagement portions 2222C), whereby one end portion or both end portions of the trunk portions 2221 are connected to each other by the fitting flange portion 2222. The fitting inlet 2222B of the integrated fitting flange portion 2222 is provided with a protruding engagement stopper portion 2222D, so that the engagement state of the engagement receiving portion 2221C and the engagement portion 2222C can be maintained. In this configuration, the number of structural components can be reduced, and the flange assembly work to the pair of trunk portions 2221 can be performed at a time, so that improvement in manufacturing efficiency can be achieved.

In the embodiment shown in fig. 13 (a), a separate C-shaped fitting flange portion 2223 is fitted to each trunk portion 2221 from above in the figure at the other end portion of each trunk portion 2221, and the engagement receiving portion 2221C is engaged with the engagement portion 2223C, so that the engaged state can be maintained by the engagement limiting portion 2223D. Alternatively, in the embodiment shown in fig. 13 (b), the fitting flange portion 2222 is integrally fitted to the other end portion of each trunk portion 2221 in the same manner as described above.

If a separate fitting flange portion 2222 is fitted to the trunk portion 2221 of each of fig. 13 (a), even if the coils are designed to be different from each other in number of turns (number of windings), even if the coils are designed to be different in length dimension, the fitting portions of the fitting flange portions 2222 can be adjusted in accordance with the length dimension of each coil. On the other hand, if the arrangement is adopted in which the integrated fitting flange portion 2222 is also provided between the other end portions of the trunk portion 2221 in fig. 13 (b), the number of structural components of the reactor can be reduced. Further, the flange fitting work to the other end portions of the pair of trunk portions 2221 can be performed at a time, and thus the manufacturing efficiency can be improved.

The third embodiment of the second group shown in fig. 14 shows a reactor frame 2320 corresponding to three-phase ac, and is provided with three coils, similar to the manner of fig. 13 (b) as a whole. The reactor frame 2320 of this embodiment includes three trunk portions 2321, and the three trunk portions 2321 are arranged in a parallel state (a state of being aligned in a direction orthogonal to an axial direction of each trunk portion 2321). The two ends of each trunk 2321 are connected by the integrated fitting flange portions 2323 and 2323.

The integrated assembly flange 2323 is provided with three fitting hollow portions 2323A and three fitting inlets 2323B in a laterally aligned state, and is assembled in an erect state at the end of each trunk 2321, and engages the engagement receiving portion 2321C with the engagement portion 2323C, and the engagement state can be maintained by the engagement limiting portion 2323D. In this embodiment, as in fig. 13 a, the integrated fitting flange portion 2323 may be fitted to only one of both end portions of each trunk portion 2321 to connect the trunk portions 2321, and a separate fitting flange portion (not shown) may be fitted to each trunk portion 2321 at the other end portion.

In the above-described embodiments of the second group, the groove-shaped engagement receiving portions 2121C, 2221C, 2321C are formed on the four surfaces of the outer peripheral surfaces of the rectangular tubular trunk portions 2121, 2221, 2321, but the present invention is not limited thereto. The range of forming the engagement receiving portion is not limited as long as the engagement portion can be engaged with the outer peripheral surface of the trunk portion. For example, a groove-shaped engagement receiving portion may be formed by selecting one or more of three surfaces of the outer peripheral surface of the rectangular cylindrical main portion, which can be opposed to the inner edge portion (engagement portion) of the fitting flange portion, or may be formed at a corner portion of the outer peripheral surface of the main portion. In addition, the cylindrical main body portion may be configured such that, when the fitting flange portion is formed in an arc shape in response thereto, a groove-shaped engagement receiving portion is formed in a portion of the outer peripheral surface of the main body portion that can face an inner edge portion (engagement portion) of the fitting flange portion, and the engagement receiving portion does not need to be formed over the entire periphery of the outer peripheral surface of the main body portion.

In the second group of embodiments, the engagement receiving portions 2121C, 2221C, 2321C are formed of grooves having rectangular cross sections, and the cross sections of the engagement portions 2122C, 2222C, 2223C, 2323C are rectangular, but the present invention is not limited thereto. The key is that the engagement portion and the engagement receiving portion are not limited as long as they can engage with each other.

For example, as shown in the fourth embodiment of the second group in fig. 15, in the reactor frame 2420, the engagement receiving portion 2421C may be formed of a groove having a V-shaped cross section and provided in the trunk portion 2421, and the engagement portion 2422C may be formed of a ridge having a sharp cross section and provided in the opening edge portion of the fitting hollow portion 2422A of the fitting flange portion 2422. If the engagement receiving portions 2421C are formed of grooves having a V-shaped cross section, the distance between the engagement receiving portions 2421C can be easily set narrower than in the case of forming grooves having a rectangular cross section, and the selectivity of the fitting position of the fitting flange portions 2422 can be improved, and the adjustment of the distance between the fitting flange portions 2422 fitted to the both end portions of the trunk portion 2421 can be improved.

In the above-described embodiments of the second group, the plurality of engagement receiving portions 2121C, 2221C, 2321C provided in the trunk portions 2121, 2221, 2321 are groove structures, and the engagement portions 2122C, 2222C, 2223C, 2323C provided in the fitting flange portions 2122, 2222, 2223, 2323 are ridge structures, respectively, but the present invention is not limited thereto. The key is that any combination of the engaging portion and the engaging receiving portion may be employed as long as the engaging portion is configured to be able to select the engaging position to be engaged to adjust the interval between the fitting flange portions. For example, the engagement receiving portions provided on the outer peripheral surface of the trunk portion may be formed by protrusions or pin-shaped projections, and the engagement portions provided on the opening edge portions of the fitting hollow portion of the fitting flange portion may be formed by grooves.

In the second group of embodiments, the engagement receiving portions 2121C, 2221C, 2321C provided in the trunk portions 2121, 2221, 2321 are formed in plural so that the positions in the axial direction of the trunk portions 2121, 2221, 2321 are different, but the present invention is not limited thereto. The engaging portion is not limited as long as at least one of the engaging receiving portion and the engaging portion is formed in plural so as to differ in position in the axial direction of the trunk portion. For example, the opening edge portion of the fitting hollow portion of the fitting flange portion may be expanded in the plate thickness direction of the fitting flange portion (in other words, the axial direction of the stem portion), and a plurality of groove-shaped engagement receiving portions may be provided on the expanded edge portion, which are offset in the plate thickness direction of the fitting flange portion (in the axial direction of the stem portion). The engaging portion on the trunk portion to which the engaging receiving portion is engaged may be constituted by a single projecting strip, or a plurality of projecting strips may be arranged so as to be offset in the axial direction of the trunk portion so as to match the pitch of the plurality of engaging receiving portions. However, if the engaging portion on the trunk portion is formed of a bead, a protrusion, or the like and protrudes from the outer peripheral surface of the trunk portion, there is a risk that the engaging portion (bead, protrusion, or the like) is caught on the inner peripheral surface of the coil in the coil mounting step, and the assembly operation is stopped. In contrast, if the engaging portion on the trunk portion is configured not to protrude from the outer peripheral surface of the trunk portion (such as a groove or recess formed by recessing the outer peripheral surface), it is preferable that the trunk portion is difficult to be caught by the inner peripheral surface of the coil in the coil mounting step, and the assembling work of the reactor is easy to be performed without stagnation.

In the second group of embodiments, the engagement limiting portions 2122D, 2222D, 2223D, 2323D having the protruding structure are exemplified as the engagement limiting portions of the present invention, but the present invention is not limited thereto. The key is that the engagement limiting portion may be any structure as long as the engagement state between the engagement portion and the engagement receiving portion can be maintained.

For example, as shown in the fifth embodiment of the second group in fig. 16, in the reactor frame 2520, the engagement stopper portion may be constituted by a concave portion 2521E formed on the outer peripheral surface of the main body portion 2521 and a convex portion 2522E protruding from the fitting flange portion 2522, and the engagement state of the engagement receiving portion 2521C and the engagement portion 2522C (the fitting state of the fitting flange portion 2522) may be maintained by the engagement of the concave portion 2521E and the convex portion 2522E. Alternatively, a rectangular member (not shown) capable of closing the fitting entrance of the fitting flange portion may be used as the engagement stopper portion, and the fitting entrance of the fitting flange portion fitted to the trunk portion may be closed by the engagement stopper portion (rectangular member) to maintain the engagement state of the engagement portion and the engagement receiving portion, thereby preventing the fitting flange portion from coming off the trunk portion.

In the second group of embodiments, the assembly flanges 2122, 2222, 2223, 2323 are formed of a single member having a substantially C-shape or a substantially E-shape, but the present invention is not limited thereto. The key is that the fitting flange portion may have any structure as long as it can be fitted to the other end portion of the trunk portion. For example, the two substantially C-shaped frame members may be opposed to each other to form a rectangular frame-shaped fitting flange portion, and the fitting flange portion may be fitted to the trunk portion by sandwiching the trunk portion between the two frame members in the flange fitting step and engaging the end portions of the frame members with each other in this state.

The coil 2110 described in each embodiment of the second group is formed by winding a flat wire in an edgewise manner, but the present invention is not limited thereto. The key is that the configuration is not limited as long as it is a coil formed by winding an electric wire. For example, a coil formed by winding a round wire (wire having a circular cross section) may be applied to the reactor and the method for manufacturing the reactor of the present invention.

Claims

1. A reactor skeleton is characterized by comprising:

A main body portion which has a hollow cylindrical shape and is capable of being provided with a coil in a wound state on an outer peripheral portion; and flange parts provided at both ends of the trunk part,

The flange provided at one end of the flange provided at the both ends is a fixed flange fixed to the main body, the flange provided at the other end is an assembling flange capable of assembling the coil after the coil is arranged on the main body,

The fitting flange portion includes an engaging portion engaged with the trunk portion side,

An engagement receiving portion for engaging the engagement portion is provided at the other end portion of the main body portion,

The engagement portion and the engagement receiving portion are engaged by selecting engagement positions of each other, so that the distance between the fixing flange portion and the fitting flange portion can be adjusted.

2. The reactor skeleton according to claim 1, wherein,

At least one of the engaging portion and the engaging receiving portion is formed in plurality so as to be different in position from the fixing flange portion.

3. The reactor skeleton according to claim 1, wherein,

The engagement receiving portion is provided on an outer peripheral surface of the trunk portion.

4. The reactor skeleton according to claim 1, wherein,

The reactor frame includes an engagement limiting portion that can maintain an engagement state between the engagement portion and the engagement receiving portion.

5. The reactor skeleton according to claim 1, wherein,

The reactor frame includes a pair of the trunk portions arranged in parallel, the fixing flange portion is provided at one end portion of each of the trunk portions, and the fitting flange portion is fitted to the other end portion of each of the trunk portions from the adjacent side.

6. The reactor skeleton according to claim 1, wherein,

The reactor frame includes a plurality of the trunk portions arranged in parallel, and at least one of the fixing flange portion fixed to one end portion of each trunk portion and the fitting flange portion fitted to the other end portion of each trunk portion is integrated.

7. A reactor skeleton is characterized by comprising:

The flange parts provided at both end parts are fitting flange parts capable of fitting to the trunk part,

Two ends of the main body part are respectively provided with an engaging receiving part for engaging the engaging part,

The engagement portions and the engagement receiving portions are engaged by selecting engagement positions therebetween, whereby the interval between the fitting flange portions can be adjusted.

8. The reactor skeleton according to claim 7, wherein,

At least one of the engaging portion and the engaging receiving portion is formed in plurality so as to have different positions in the axial direction of the trunk portion.

9. The reactor skeleton according to claim 7, wherein,

10. The reactor skeleton according to claim 7, wherein,

11. The reactor skeleton according to claim 7, wherein,

The reactor frame includes a pair of trunk portions arranged in parallel, and the fitting flange portions fitted to at least one end portion of each trunk portion from an adjacent side.

12. The reactor skeleton according to claim 7, wherein,

The reactor frame includes a plurality of trunk portions arranged in parallel, and at least one of the fitting flange portion fitted to one end portion of each trunk portion and the fitting flange portion fitted to the other end portion of each trunk portion is integrated.

13. A reactor is characterized in that,

The reactor is configured such that a coil is disposed in a wound state around the trunk portion of the reactor skeleton as defined in any one of claims 1 to 12, and the magnetic core is assembled such that a leg portion of the magnetic core is accommodated in a hollow portion of the trunk portion.

14. A method for manufacturing a reactor, wherein a coil is arranged around a trunk portion of a reactor frame having flange portions at both end portions of the trunk portion in a hollow cylindrical shape, the coil is wound around the trunk portion, and a leg portion of a magnetic core is housed in a hollow portion of the trunk portion,

The manufacturing method of the reactor is characterized by comprising the following steps:

a skeleton forming step of forming the skeleton for a reactor according to any one of claims 1 to 6;

A coil forming step of winding an electric wire to form a coil;

A coil mounting step of passing the trunk portion through an air core portion of the coil to mount the coil around the trunk portion;

A flange portion assembling step of assembling the flange portion at a predetermined position of the other end portion of the trunk portion to which the coil is attached; and

And a core assembly step of assembling the magnetic core so as to accommodate the leg portions of the magnetic core in the hollow portion of the main portion provided with the coil and the fitting flange portion.

15. A method for manufacturing a reactor, wherein a coil is arranged around a trunk portion of a reactor frame having flange portions at both end portions of the trunk portion in a hollow cylindrical shape, the coil is wound around the trunk portion, and a leg portion of a magnetic core is housed in a hollow portion of the trunk portion,

a skeleton forming step of forming the skeleton for a reactor according to any one of claims 7 to 12;

A coil forming step of winding an electric wire to form a coil;

A first flange portion assembling step of assembling one of the flange portions at a predetermined position of one end portion of the main portion;

A second flange portion mounting step of mounting one of the mounting flange portions at a predetermined position of the other end portion of the main body portion, the other mounting flange portion being mounted with the coil; and

And a core assembly step of assembling the magnetic core so as to house the leg portions of the magnetic core in the hollow portion of the main portion provided with the coil and the fitting flange portion.