JP7437989B2 - Case, reactor, electronic equipment and reactor manufacturing method - Google Patents

Description

The present disclosure relates to a case, a reactor, an electronic device, and a method for manufacturing a reactor.

Conventionally, a reactor including a core made up of a plurality of core components is known. For example, in Japanese Patent Application Laid-Open No. 2010-27692, in order to fix the position of the core components with gaps provided between the core components, through holes are formed in the multiple core components, and a shaft is inserted into the through holes. The core parts are fixed by inserting the members. The shaft member is fixed to the case via a coil spring.

Japanese Patent Application Publication No. 2010-27692

In the conventional reactor described above, in order to fix the position of a plurality of core components with gaps provided between them, it is necessary to prepare a plurality of components such as a shaft member, a coil spring, and a case. Furthermore, the manufacturing process of a reactor using the above-mentioned core made of a plurality of core parts is complicated.

Therefore, an object of the present disclosure is to provide a reactor and its manufacturing method that can simplify the manufacturing process of the reactor, a case that holds a core that constitutes the reactor, and an electronic device using the reactor. do.

A case according to the present disclosure includes an outer shell portion and a rib portion, and the outer shell portion holds therein a core that constitutes a reactor. The core includes multiple core components. The rib portion protrudes from the inner surface of the outer shell portion and is disposed between the plurality of core components.

A reactor according to the present disclosure includes the case, a core, and a winding. The core is housed inside the case. The winding is wound around a part of the case.

An electronic device according to the present disclosure includes the above reactor and a substrate. A reactor is mounted on the board.

In the reactor manufacturing method according to the present disclosure, a case, a reactor core, and a winding are prepared. The core includes multiple core components. The case includes an outer shell portion and a rib portion. The outer shell retains the core inside. The rib portion protrudes from the inner surface of the outer shell portion. The rib portion is arranged between the plurality of core parts. The outer shell has an annular shape that revolves around the central axis. Furthermore, in the reactor manufacturing method, a plurality of core components are housed inside the case. At this time, the rib portion is placed between the plurality of core components. Furthermore, in the reactor manufacturing method, the winding is arranged so as to wrap around a part of the case.

According to the above, it is possible to obtain a reactor and its manufacturing method that can simplify the manufacturing process of the reactor, a case that holds a core constituting the reactor, and an electronic device using the reactor.

FIG. 2 is a schematic perspective view of a first portion of a case that constitutes the reactor according to the first embodiment. FIG. 3 is a schematic perspective view of a second portion of the case that constitutes the reactor according to the first embodiment. FIG. 3 is a schematic perspective view of a third portion of the case that constitutes the reactor according to the first embodiment. 1 is a schematic perspective view of a reactor according to Embodiment 1. FIG. 5 is an exploded schematic diagram of the reactor shown in FIG. 4. FIG. 1 is a partially enlarged schematic diagram of an electronic device according to Embodiment 1. FIG. 3 is a flowchart for explaining a method for manufacturing a reactor according to Embodiment 1. FIG. FIG. 2 is a schematic perspective view for explaining a method for manufacturing a reactor according to Embodiment 1. FIG. FIG. 3 is a schematic perspective view of a first portion of a case that constitutes a reactor according to a second embodiment. FIG. 3 is a schematic perspective view of a third portion of a case that constitutes a reactor according to a second embodiment. FIG. 3 is a schematic perspective view of a reactor according to Embodiment 2. FIG. 12 is an exploded schematic diagram of the reactor shown in FIG. 11. FIG. 1 is a partially enlarged schematic diagram of an electronic device according to Embodiment 1. FIG.

Embodiments of the present disclosure will be described below. In addition, the same reference numerals are given to the same structure, and the description thereof will not be repeated.

Embodiment 1.
<Case and reactor configuration>
FIG. 1 is a schematic perspective view of a first portion of a case that constitutes a reactor according to a first embodiment. FIG. 2 is a schematic perspective view of a second portion of the case that constitutes the reactor according to the first embodiment. FIG. 3 is a schematic perspective view of the third portion of the case that constitutes the reactor according to the first embodiment. FIG. 4 is a schematic perspective view of the reactor according to the first embodiment. FIG. 5 is an exploded schematic diagram of the reactor shown in FIG. 4.

The case shown in FIGS. 1 to 3 is a member that internally holds the core 60 that constitutes the reactor 100 shown in FIGS. 4 and 5. The case 1 mainly includes a first part 10, a second part 20, a third part 30, a rib part 11, and a projection part 66. 30 is assembled together is called an outer shell. The outer shell has an annular shape that revolves around the central axis 65. The outer shell portion holds the core 60 that constitutes the reactor 100 inside. As shown in FIG. 5, the core 60 includes a plurality of core parts 61 and 62. The rib portion 11 protrudes from the inner surface of the outer shell portion and is arranged between the plurality of core components 61 and 62. The rib portion 11 functions as a spacer that defines the distance between the core components 61 and 62 when the core components 61 and 62 are arranged side by side. Furthermore, the rib portion 11 has a function as a guide for positioning the plurality of core components 61 and 62.

In the case 1, the outer shell portion includes a first portion 10 shown in FIG. 1, a second portion 20 shown in FIG. 2, and a third portion 30 shown in FIG. 3. Further, the outer shell portion includes connection portions 12a, 12b, 13a to 13d, 21a, 21b, 22a to 22d, and 31a to 31d. The connection portion snap-fits the first portion 10, second portion 20, and third portion 30 together.

More specifically, the first portion 10 shown in FIG. 1 is a component that constitutes the bottom of the outer shell of the case 1. The bottom wall of the first portion 10 has a U-shape. A protrusion 66 is formed at the end of the bottom wall of the first portion 10 . In the first portion 10 shown in FIG. 1, two protrusions 66 are formed at the end thereof. The protrusion 66 includes the leg portion 15 and the fixing portion 16. The leg portion 15 is formed to protrude from the bottom surface of the first portion 10, which is located on the opposite side to the inner surface (the top surface in FIG. 1) of the bottom wall. The fixing portion 16 is connected to the tip of the leg portion 15 and extends in a direction different from the extending direction of the leg portion 15 (for example, in a direction along the bottom wall of the first portion 10). A hole 17 is formed in the fixing portion 16 . Although the fixing portion 16 has a rectangular planar shape, it may have any other arbitrary shape such as a triangle or a circle. The distance L1 between the tip of the leg portion 15 and the end of the fixed portion 16 located on the opposite side of the tip is 15 mm or more.

The first portion 10 has a side wall surrounding the outer periphery of the bottom wall. In the first portion 10, as shown in FIG. 5, a region (recess) surrounded by the bottom wall and the side walls is formed on the inner surface side of the bottom wall. The recess is a region for holding a plurality of core components 61 and 62. A rib portion 11 is formed on the inner surface of the recess. The rib portion 11 is a convex portion that protrudes from the inner surface of the recess (the inner surface of the side wall). The shape of the rib portion 11 may be a band-like shape as shown in FIG. 1, but may be other shapes such as a rod-like shape. The cross-sectional shape of the rib portion 11 in a plane perpendicular to the direction in which the rib portion 11 extends is a rectangular shape as shown in FIG. 1, but it may have another shape. A plurality of rib portions 11 are arranged, for example, at equal intervals on the side wall constituting the recess of the first portion 10. Furthermore, rib portions 11 are formed on opposing side walls of the recess.

As shown in FIG. 1, the first portion 10 is formed with connecting portions 12a, 12b, 13a to 13d for connecting to the second portion 20 and the third portion 30, which are other components. The connecting portions 12a and 12b are formed on the outer periphery of the recessed portion of the first portion 10. From a different perspective, the connecting portions 12a and 12b are formed so as to protrude from the upper end surface of the side wall that constitutes the outer peripheral side surface of the first portion 10. The connecting portion 12a and the connecting portion 12b are formed on opposing portions of the side wall of the first portion 10, respectively. The connecting parts 12a and 12b are elastically deformable loop parts having an opening in the center. The connecting portions 13a to 13d are formed on opposing portions of the side walls of the first portion 10. Specifically, connection portions 12b, 13a, and 13b are formed in a first sidewall portion that is one of the opposing portions of the sidewalls. Connecting portions 12a, 13c, and 13d are formed in the second side wall portion, which is the other corresponding portion of the side wall.

In the first portion 10, side walls constituting the outer peripheral side surface are formed in three directions on the outer periphery of the first portion 10. A third portion 30 is connected to a portion of the outer peripheral portion of the first portion 10 where no side wall is formed, as will be described later. A second portion 20 is connected to the upper surface side of the first portion 10 as described later.

The first portion 10 shown in FIG. 1 is made of resin. The first part 10 is molded using an injection molding method or a 3D printer. As the resin material used for the first portion 10, for example, a resin having a heat resistance temperature of 120 degrees or higher can be used. Examples of resin materials that can be used for the first portion 10 include polybutylene terephthalate resin (PBT), polyphenylene sulfide resin (PPS), polyamide resin (PA), polycarbonate resin (PC), and liquid crystal polymer resin (LCP).

A pair of ribs 11 are provided on opposing inner surfaces of the side walls of the first portion 10 to define a gap between the core parts 61,62. The height L5 of the rib portion 11 from the inner surface of the side wall may be 25% or less of the distance L6 between opposing inner surface portions of the side wall. Furthermore, on the inner peripheral side of the first portion 10, the height L8 of the side wall and the length L7 of the rib portion 11 are the same. Note that the direction in which the rib portion 11 extends is the insertion direction of the core component 61 when the core component 61 is inserted into the first portion 10 in the reactor manufacturing method described below.

The height L8 of the side wall of the first portion 10 may be greater than or equal to 40% and less than or equal to 50% of the height L9 (see FIG. 5) of the core component 61 when the core component 61 is installed in the first portion 10. . In order to form a gap between the core parts 61 and 62, the thickness t1 of the rib portion 11 may be 1 mm or less. The distance L10 between two adjacent rib portions 11 is set to a value of the dimension of the core component 61 + 0.15 mm. This interval L10 takes into consideration the dimensional variation of the core component 61.

In order to connect and fix the first portion 10 and the second portion 20, the first portion 10 is formed with at least two connecting portions 12a, 12b, 13a, and 13c. The structure of the connecting portions 12a, 12b, 13a, and 13c is a snap-fit structure. The connecting portions 12a, 12b, 13a, and 13c are installed on the side connected to the second portion 20 (open surface side).

The distance L12 between the connecting portion 12a and the connecting portion 13c in the first portion 10 is 65% or more of the width L11 of the first portion 10 when viewed from the side where the connecting portions 12a and 13c are formed. It may be less than %. It is preferable that the connecting portions 12a and 13c are arranged at equal distances from the center of the width L11 of the first portion 10. The height L17 of the connecting portion 12a may be greater than or equal to 40% and less than or equal to 50% of the length L7 of the rib portion 11. The protrusion height L13 of the convex portion corresponding to the fitting height of the connecting portion 13a is preferably at least 1 mm or more and less than the thickness of the side wall.

Regarding the protrusion 66, the thickness of the leg 15 may be the same as the thickness of the side wall, or may be thicker than the side wall. The thickness of the fixed part 16 may be the same as the thickness of the leg part 15, or may be thicker than the thickness of the leg part 15. The diameter of the hole 17 formed in the fixing part 16 may be, for example, 5 mm or more. The hole 17 may have a threaded structure on its inner peripheral surface. As will be described later, the reactor 100 may be fixed to a member such as the substrate 91 by inserting a fixing screw 92 (see FIG. 6) such as a bolt into the hole 17.

The core component 62 (see FIG. 5) disposed on the side of the first portion 10 where the connecting portion 13b is formed is inserted in the insertion direction of the core component 61 into the first portion 10 (direction along the central axis 65 in FIG. 5). ) along the first portion 10. Further, the core component 62 can also be arranged in the first portion 10 along the direction of the central winding axis 67 of the winding 41 shown in FIG. This is because the bottom wall and side wall of the first portion 10 are not provided with any protrusions or the like that would obstruct the insertion operation of the core component 62 as described above. In addition, in the first portion 10, the width of the area including the rib portion 11 that contacts the surface of the core component 62 (the total length of the width L15 and the width L16 in FIG. 1) is such that It may be 40% or more and 60% or less with respect to the width L14 of the portion.

In order to connect and fix the first portion 10 and the third portion 30, the first portion 10 is formed with at least two connecting portions 13b and 13d. The structure of the connecting portions 13b and 13d is a snap-fit structure. The connecting portions 13b and 13d are installed on the side connected to the third portion 30 (the open end side in the U-shaped planar shape of the first portion 10). The connecting portions 13b and 13d of the first portion 10 are arranged at the ends of the side walls farther from the bottom wall in the height direction, but may be arranged at the center of the side walls in the height direction. The structure of the connecting portions 13b and 13d may be similar to the structure of the connecting portions 13a and 13c described above.

Note that the connecting portions 12a, 12b, 13a, 13b, 13c, and 13d may have a structure other than that shown in FIG. 1. For example, the snap-fit structure of the connecting parts 12a, 12b, 13a, 13b, 13c, and 13d can be a cantilever type with a hook-shaped holding part at the tip of a leaf spring, a ball-and-socket type with a ball joint, or a cylindrical periphery. A structure including a holding portion may also be used.

As shown in FIG. 2, the second portion 20 is a member connected to the upper surface side of the first portion 10, and includes an upper wall having a U-shaped planar shape, and a side wall forming the outer peripheral side of the upper wall. and has. The side walls are formed in three directions around the outer periphery of the top surface. In addition, in FIG. 2, the second portion 20 is displayed with its upper surface facing downward. In the second portion 20, a region surrounded by the upper surface and the side wall serves as a recess in which the core 60 is placed. A rib portion 11 is formed on the inner surface of the recess. The structure of the recess is similar to the structure of the recess of the first portion 10 shown in FIG. Although the second portion 20 shown in FIG. 2 is not provided with the protrusion 66, the protrusion 66 may be formed on the second portion 20 instead of the first portion 10.

The second portion 20 is connected to the first portion 10 such that the end of the side wall faces the upper end surface of the side wall of the first portion 10 . The second portion 20 is also formed with connecting portions 21a, 21b, 22a to 22d for connecting with the first portion 10 and the third portion 30. The connecting portions 21a and 21b are formed on the outer periphery of the recessed portion of the second portion 20. From a different perspective, the connecting portions 21a and 21b are formed so as to protrude from the end portions of the side walls forming the outer circumferential side surface of the second portion 20. The connecting portion 21a and the connecting portion 21b are formed on opposing portions of the side wall of the second portion 20, respectively. The connecting portions 21a and 21b have the same structure as the connecting portions 12a and 12b of the first portion 10. The connecting portions 22a to 22d are formed on opposing portions of the side walls of the second portion 20. Specifically, connecting portions 21b, 22a, and 22b are formed in a third side wall portion that is one of the opposing portions of the side walls. Connection portions 21a, 22c, and 22d are formed in the fourth sidewall portion, which is the other corresponding portion of the sidewall. A third portion 30 is connected to a portion of the second portion 20 where a side wall is not formed, as will be described later.

The second portion 20 shown in FIG. 2 is made of resin. The second portion 20 is molded using an injection molding method or a 3D printer. As the resin material used for the second portion 20, the same resin material as the resin material used for the first portion 10 described above can be applied. For example, as the resin material used for the second portion 20, a resin having a heat resistance temperature of 120 degrees or higher can be used. Examples of resin materials that can be used for the second portion 20 include polybutylene terephthalate resin (PBT), polyphenylene sulfide resin (PPS), polyamide resin (PA), polycarbonate resin (PC), and liquid crystal polymer resin (LCP).

The height L28 of the side wall of the second portion 20 is such that when the second portion 20 is connected to the first portion 10 as shown in FIG. 4, a gap 51 is formed between the first portion 10 and the second portion 20. It is said to be of such height. The size of the gap 51 is, for example, 1 mm.

A pair of ribs 11 are provided on the opposing inner surfaces of the side walls of the second portion 20 in the same way as in the first portion 10 in order to define the gap between the core parts 61 and 62. The height L25 of the rib portion 11 from the inner surface of the side wall may be 25% or less of the distance L26 between opposing inner surface portions of the side wall. Further, on the inner peripheral side of the second portion 20, the height L28 of the side wall and the length L27 of the rib portion 11 are the same. Note that the direction in which the rib portion 11 extends is the direction in which the second portion 20 is connected to the first portion 10 and the second portion 20 is placed over the core components 61 and 62 in the reactor manufacturing method described below. 20 moving directions.

The height L28 of the side wall of the second portion 20 may be 40% or more and 50% or less of the height L9 of the core component 61 (see FIG. 5). In order to form a gap between the core parts 61 and 62, the thickness t1 of the rib portion 11 may be 1 mm or less. The distance L30 between two adjacent rib portions 11 is set to a value of the dimension of the core component 61 + 0.15 mm. This interval L30 takes into consideration the dimensional variation of the core component 61.

In order to connect and fix the first portion 10 and the second portion 20, the second portion 20 is formed with at least two connecting portions 21a, 21b, 22a, and 22c. The structure of the connecting portions 21a, 21b, 22a, and 22c is a snap-fit structure. The connecting portions 21a, 21b, 22a, and 22c are installed on the side connected to the first portion 10 (open surface side).

The distance L32 between the connecting portion 21a and the connecting portion 22c in the second portion 20 is 65% or more of the width L31 of the second portion 20 when viewed from the side where the connecting portions 21a and 22c are formed. It may be less than %. It is preferable that the connecting portions 21a and 22c are arranged at equal distances from the center of the width L31 of the second portion 20. The height L37 of the connecting portion 21a may be greater than or equal to 40% and less than or equal to 50% of the length L27 of the rib portion 11. The protrusion height L33 of the convex portion corresponding to the fitting height of the connecting portion 21a is preferably at least 1 mm or more and less than the thickness of the side wall.

In order to connect and fix the second portion 20 and the third portion 30, the second portion 20 is formed with at least two connecting portions 22b and 22d. The structure of the connecting portions 22b and 22d is a snap-fit structure. The connecting portions 22b and 22d are installed on the side connected to the third portion 30 (the open end side in the U-shaped planar shape of the second portion 20). Although the connecting portions 22b and 22d of the second portion 20 are arranged at the ends of the side walls farther from the upper wall in the height direction, they may be arranged at the center of the side walls in the height direction. The structure of the connecting portions 22b and 22d may be similar to the structure of the connecting portions 22a and 22c described above.

Note that the structures of the connecting portions 21a, 21b, 22a, 22b, 22c, and 22d may be other than the structure shown in FIG. 2. For example, the snap-fit structure of the connecting parts 21a, 21b, 22a, 22b, 22c, and 22d includes a cantilever type with a hook-shaped holding part at the tip of a leaf spring, a ball-and-socket type with a ball joint, and a cylindrical periphery. A structure including a holding portion may also be used.

As shown in FIG. 3, the third portion 30 is a member connected to the outer circumferential portion of the first portion 10 and the second portion 20 on which side walls are not formed, and includes a plate-shaped main body portion and a main body portion. It mainly has a protrusion 66 formed at the end of the main body, and connection parts 31a to 31d formed at the outer periphery of the main body. The main body portion has, for example, a rectangular planar shape. The planar shape of the main body portion may be other shapes. The structure of the protrusion 66 is similar to the structure of the protrusion 66 in the first portion 10 shown in FIG. The leg portion 15 of the protrusion portion 66 is formed to extend in a direction along the main surface of the main body portion of the third portion 30 . Two protrusions 66 are formed at an interval on the outer periphery of the main body of the third portion 30.

The connecting portions 31a to 31d are respectively formed in opposing areas on the outer peripheral portion of the main body. Specifically, in the main body of the third portion 30, connecting portions 31a and 31b are formed at one end. In addition, connecting portions 31c and 31d are formed at the other end of the main body portion located on the opposite side from the one end. The connecting portions 31a to 31d have the same structure as the connecting portions 12a and 12b of the first portion. The connecting portions 31a to 31d are formed to protrude in a direction opposite to the direction in which the fixing portion 16 of the protruding portion 66 extends.

The third portion 30 shown in FIG. 3 is made of resin. The third portion 30 is molded using an injection molding method or a 3D printer. As the resin material used for the third portion 30, the same resin material as the resin material used for the first portion 10 or the second portion 20 described above can be applied. For example, as the resin material used for the third portion 30, a resin having a heat resistance temperature of 120 degrees or higher can be used. Examples of resin materials that can be used for the third portion 30 include polybutylene terephthalate resin (PBT), polyphenylene sulfide resin (PPS), polyamide resin (PA), polycarbonate resin (PC), and liquid crystal polymer resin (LCP). The first portion 10, the second portion 20, and the third portion 30 may be made of the same material, or may be made of different materials.

The width L40 of the third portion 30 is equal to the width of the core component 62 plus the thickness of the side wall of the first portion 10. Moreover, the height L41 of the third portion 30 is the same as the total height L41 of the first portion 10 and the second portion 20 in the reactor 100 shown in FIG. In the reactor 100 shown in FIG. It is equal to the distance between the outer peripheral surface (top surface) and the outer circumferential surface (top surface).

The third portion 30 is formed with at least four connecting portions 31a to 31d. The structures of the connecting portions 31a to 31d may be similar to the connecting portions 12a and 12b of the first portion 10. For example, the height L57 of the connecting portions 31a to 31d may be greater than or equal to 40% and less than or equal to 50% of the length L7 of the rib portion 11 shown in FIG. When the third portion 30 is connected to the first portion 10 and the second portion 20 as shown in FIG. 4, the positions of the connecting portions 31a to 31d are as shown in FIG. It is determined to overlap with 13b, 22b, and 13d.

The reactor 100 shown in FIGS. 4 and 5 mainly includes a case 1 in which the first portion 10, the second portion 20, and the third portion 30 are connected, a core 60, and a winding 41. The core 60 is housed inside the case 1. The winding 41 is wound around a part of the case 1. The case 1 has an annular shape when viewed from the direction along the central axis 65. Regarding the core 60, a plurality of core parts 61 and 62 are arranged in an annular shape. One of the two windings 41 is wound around a portion of the annular case. The other one of the two windings 41 is wound around another part of the annular case 1 that faces the above part through the central opening.

In case 1, connecting portions 12a, 12b, 13a, and 13c of first portion 10 are connected to connecting portions 22a, 22c, 21a, and 21b of second portion 20, respectively. Furthermore, the connecting portions 13b and 13d of the first portion 10 are connected to the connecting portions 31b and 31d of the third portion 30, respectively. The connecting portions 22b and 22d of the second portion 20 are connected to the connecting portions 31a and 31c of the third portion 30, respectively. A rib portion 11 is arranged between core parts 61 and 62 that constitute the core 60. By arranging the core parts 61 and 62 inside the case 1 in this way, the distance between the core parts 61 and 62 is automatically defined by the rib portion 11.

<Configuration of electronic equipment>
FIG. 6 is a partially enlarged schematic diagram of the electronic device according to the first embodiment. The electronic device 200 shown in FIG. 6 mainly includes the reactor 100 and a substrate 91. A reactor 100 is mounted on the substrate 91. Specifically, in the reactor 100, the case 1 is provided with a protrusion 66 that protrudes outward from the first portion 10 or the third portion 30 that constitutes the outer shell. The protrusion 66 extends in a direction intersecting a winding center axis 67 (see FIG. 5) around which the winding 41 is wound. The hole 17 in the fixing part 16 of the protrusion 66 is arranged to overlap with the screw hole formed in the substrate 91. A fixing screw 92 is inserted and fixed into the hole 17 and the screw hole. As shown in FIG. 6, a length L2 of the protrusion 66 extending outward from the case 1 is longer than a distance L3 from the surface of the case 1 to the outer periphery of the winding 41.

<Reactor manufacturing method>
FIG. 7 is a flowchart for explaining the reactor manufacturing method according to the first embodiment. FIG. 8 is a schematic perspective view for explaining the method for manufacturing the reactor according to the first embodiment.

In the reactor manufacturing method according to the present disclosure, a preparation step (S10) is performed. In this step (S10), the first portion 10, second portion 20, and third portion 30, which will become the case 1 described above, the core 60, and the winding 41 are prepared. The core 60 consists of a plurality of core parts 61 and 62.

Next, a first assembly step (S20) is performed. In this step (S20), the core components 61 and 62 are placed in the recessed portion of the first portion 10. Note that at this time, the core component 62 disposed on the side of the first portion 10 shown in FIG. 8 on which the side wall is not formed (the third portion 30 side in the outer shell portion) is not yet disposed in the recess of the first portion 10. In this state, the second portion 20 is connected to the first portion 10. In this state, the structure including the first portion 10, the second portion 20, and the core components 61, 62 has a U-shape when viewed from the direction along the central axis 65 in FIG. In other words, when the case 1 is finally formed, the opening located at the center is connected to the outside in one direction.

Next, a winding arrangement step (S30) is performed. In this step (S30), the winding 41 in a wound state as shown in FIG. Insert it into a structure consisting of. Specifically, the winding 41 is arranged so as to wind around the area where the core components 61 are lined up.

Next, a second assembly step (S40) is performed. In this step (S40), the last core component 62 that was not placed in the step (S20) is placed inside the structure in which the first portion 10 and the second portion 20 are connected. As a result, the core parts 61 and 62 are arranged in an annular manner to form the core 60. Further, the third portion 30 is connected to the first portion 10 and the second portion 20 so as to cover the portion into which the core component 62 is inserted. In this way, the reactor 100 shown in FIG. 4 is obtained.

<Effect>
A case 1 according to the present disclosure includes an outer shell portion and a rib portion 11, and the outer shell portion holds a core 60 that constitutes a reactor 100 inside. Core 60 includes a plurality of core parts 61 and 62. The rib portion 11 protrudes from the inner surface of the outer shell portion and is arranged between the plurality of core components 61 and 62.

In this way, when the plurality of core components 61, 62 are arranged inside the case 1, the gap between the plurality of core components 61, 62 can be easily defined by the rib portion 11. Therefore, the manufacturing process of a reactor using the case 1 can be simplified.

In the case 1, the outer shell portion includes a first portion 10, a second portion 20, and connecting portions 12a, 12b, 13a to 13d, 21a, 21b, and 22a to 22d. The connecting portions 12a, 12b, 13a-13d, 21a, 21b, 22a-22d connect the first portion 10 and the second portion 20 with a snap fit.

In this case, the first portion 10 and the second portion 20 can be easily joined. As a result, the reactor manufacturing process of assembling the case 1 with the plurality of core parts 61 and 62 housed inside the case 1 can be simplified.

In the case 1, the outer shell has an annular shape that revolves around the central axis 65. The outer shell portion includes a first portion 10, a second portion 20, and a third portion 30. The first portion 10 and the second portion 20 are connected to each other in the direction along the central axis 65. The third portion 30, the first portion 10, and the second portion 20 are connected to each other in a direction intersecting the central axis 65. The outer shell portion includes connecting portions 12a, 12b, 13a to 13d, 21a, 21b, 22a to 22d, 31a to 31a for snap-fit connecting two of the first portion 10, second portion 20, and third portion 30. 31d.

In this case, the first portion 10, the second portion 20, and the third portion 30 can be easily joined. As a result, the reactor manufacturing process of assembling the case 1 with the plurality of core parts 61 and 62 housed inside the case 1 can be simplified.

The case 1 includes a protrusion 66 that protrudes outward from the outer shell. In this case, when a reactor using the case 1 has a winding 41 wound around the outer periphery of the case 1, and the reactor is mounted on a board etc., the protrusion 66 connects the board and the winding 41. A gap can be formed between them. Note that the protrusion 66 is preferably formed to protrude in a direction intersecting the central winding axis of the winding 41.

In the case 1 described above, the protrusion 66 includes the leg portion 15 and the fixing portion 16. The legs 15 protrude outward from the outer shell. The fixing part 16 is connected to the tip of the leg part 15 and extends in a direction different from the direction in which the leg part 15 extends.

In this case, by fixing the fixing portion 16 to a member such as the substrate 91 or the fixing case, the reactor 100 using the case 1 can be easily fixed to the member such as the substrate 91.

In the case 1 described above, a hole 17 is formed in the fixing part 16. In this case, by inserting a fixing screw or the like into the hole 17, the reactor 100 using the case 1 can be easily fixed to a member such as the substrate 91.

In the case 1, the distance L1 between the tip of the leg portion 15 and the end of the fixing portion 16 located on the opposite side of the tip is 15 mm or more. In this case, in the reactor 100 using the case 1, interference between the winding 41 wound around the outer periphery of the case 1 and the member to which the reactor 100 is fixed can be reliably avoided.

A reactor 100 according to the present disclosure includes the case 1, a core 60, and a winding 41. The core 60 is housed inside the case 1. The winding 41 is wound around a part of the case 1.

In this way, simply by arranging the core 60 made up of a plurality of core parts 61 and 62 inside the case 1, the interval between the core parts 61 and 62 can be accurately defined. Therefore, the reactor 100 whose manufacturing process is simplified can be obtained.

In the reactor 100, the case 1 includes a protrusion 66 that protrudes outward from the outer shell. The protrusion 66 extends in a direction intersecting the winding center axis 67 around which the winding 41 is wound. The length L2 of the protrusion 66 extending outward from the outer shell is longer than the distance L3 from the surface of the case 1 to the outer periphery of the winding 41.

In this case, when the reactor 100 is fixed to a member such as the substrate 91 or the fixing case, if the protrusion 66 is fixed to the member, problems such as interference between the member and the winding 41 can be suppressed. can.

An electronic device 200 according to the present disclosure includes the reactor 100 and a substrate 91. A reactor 100 is mounted on the substrate 91. In this case, by using the reactor 100 whose manufacturing process is simplified, the manufacturing process of the electronic device 200 can also be simplified as a result. Therefore, the manufacturing cost of the electronic device 200 can be reduced.

In the reactor manufacturing method according to the present disclosure, the case 1, the core 60 of the reactor 100, and the winding 41 are prepared (S10). Core 60 includes a plurality of core parts 61 and 62. The case 1 includes an outer shell part and a rib part 11. The outer shell retains the core 60 therein. The rib portion 11 protrudes from the inner surface of the outer shell portion. The rib portion 11 is arranged between the plurality of core components 61 and 62. The outer shell has an annular shape that revolves around the central axis 65. Furthermore, in the method for manufacturing the reactor 100, a plurality of core components 61 and 62 are housed inside the case 1 (S20). At this time, the rib portion 11 is placed between the plurality of core components 61 and 62. Furthermore, in the method for manufacturing the reactor 100, the winding 41 is arranged so as to wrap around a part of the case 1 (S30).

In this way, by arranging the plurality of core parts 61 and 62 inside the case 1, the gap between the plurality of core parts 61 and 62 is accurately defined by the rib portion 11. Therefore, the manufacturing process of the reactor can be simplified compared to the case where a separate member from the case 1 is used to define the gap between the plurality of core components 61 and 62.

In the above method for manufacturing reactor 100, the outer shell portion includes a first portion 10, a second portion 20, and a third portion 30. The first portion 10 and the second portion 20 are connectable to each other in the direction along the central axis 65. The third portion 30, the first portion 10, and the second portion 20 can be connected to each other in a direction intersecting the central axis 65. A rib portion 11 is arranged on the first portion 10 and the second portion 20. Furthermore, the step of accommodating the plurality of core components 61 and 62 (S20) includes a first step and a second step. In the first step, the first portion 10 and the second portion 20 are connected with some of the plurality of core components 61 and 62 being sandwiched between the first portion 10 and the second portion 20. In the second step, the third part 30 is combined with the first part 10 and the second part 20 while the remaining parts of the plurality of core parts 61 and 62 are arranged adjacent to the above-mentioned part of the plurality of core parts 61 and 62. Connecting. In the step of arranging the winding (S30), after the first step and before the second step, the wound wire 41 is connected to the first portion 10 and the second portion 20. The third part 30 is fitted into the case part from the direction in which it is connected.

In this case, the winding 41 to be wound around the outer periphery of the case 1 of the reactor 100 can be arranged by a simple process of fitting the winding 41 in a pre-wound state into the case portion.

Embodiment 2.
<Case configuration>
FIG. 9 is a schematic perspective view of the first portion of the case that constitutes the reactor according to the second embodiment. FIG. 10 is a schematic perspective view of the third portion of the case that constitutes the reactor according to the second embodiment.

The first part 10 and the third part 30 of the case forming the reactor shown in FIGS. 9 and 10 are combined with the second part 20 shown in FIG. 2 to form the case 1 of the reactor 100. The first portion 10 shown in FIG. 9 basically has the same configuration as the first portion 10 shown in FIG. 1, but the structure of the protrusion 66 is different from the first portion 10 shown in FIG. There is. Specifically, the protrusion 66 of the first portion 10 shown in FIG. 9 includes a leg portion 71 extending in a direction protruding from the outer peripheral surface (bottom surface) of the bottom wall of the first portion 10. The planar shape of the upper surface of the leg portion 71 when viewed from the direction along the side wall of the first portion 10 is semicircular.

The leg portion 71 has a first surface 71a, which is the upper surface described above, and a second surface 71b. The second surface 71b is a bottom surface located on the opposite side to the first surface 71a. A through hole 72 is formed in the leg portion 71 and extends from the first surface 71a to the second surface 71b. The cross-sectional shape of the through hole 72 is circular. The shape of the through hole 72 may be another polygonal shape such as a square. Further, the planar shape of the first surface 71a may be any shape other than a semicircular shape. For example, the planar shape of the first surface 71a may be a polygonal shape such as a quadrangle, or any shape including a curved outer circumference such as an ellipse.

The width L4 of the leg portion 71 may be, for example, twice or more the diameter D of the through hole 72. Further, the width L64 of the leg portion 71 may be, for example, a value equal to or greater than the sum of the thickness of the side wall and twice the diameter D of the through hole 72. The width L4 and the width L64 may each be 10 mm or more. The diameter D of the through hole 72 may be 5 mm or more. The height L2 (see FIG. 13) of the leg portion 71 is preferably longer than the distance L3 from the surface of the case 1 to the outer periphery of the winding 41 in the reactor 100.

A threaded structure may be formed on the inner surface of the through hole 72. Alternatively, an insert component having a screw hole may be inserted into the through hole 72 and fixed.

The third portion 30 shown in FIG. 10 basically has the same configuration as the third portion 30 shown in FIG. 3, but the structure of the protrusion 66 is different from the third portion 30 shown in FIG. There is. Specifically, the protrusion 66 of the third portion 30 shown in FIG. 10 has the same configuration as the protrusion 66 of the first portion 10 shown in FIG. 9 described above.

Note that in the first portion 10 shown in FIGS. 1 and 9, two or more protrusions 66 may be formed. Moreover, two or more protrusions 66 may be formed in the third portion 30 shown in FIGS. 3 and 10 as well.

<Reactor configuration>
FIG. 11 is a schematic perspective view of a reactor according to the second embodiment. FIG. 12 is an exploded schematic diagram of the reactor shown in FIG. 11.

The reactor 100 shown in FIGS. 11 and 12 basically has the same configuration as the reactor 100 shown in FIGS. 4 and 5, except that the case 1 is It is composed of three parts 30 and the second part 20 shown in FIG. Therefore, in the reactor 100 shown in FIGS. 4 and 5, the structure of the protrusion 66 is different from that of the reactor 100 shown in FIGS. 4 and 5. The reactor shown in FIGS. 11 and 12 can provide the same effects as the reactor 100 shown in FIGS. 4 and 5, and, as will be described later, when fixing the reactor 100 to a member such as the substrate 91, the protrusion 66 can be used. The protruding part 66 in the reactor 100 shown in FIGS. 11 and 12 has a columnar leg part 71 and has higher rigidity than the protruding part 66 in the reactor 100 shown in FIGS. 4 and 5. Therefore, the reactor 100 can be connected to members such as the substrate 91 with high rigidity.

Note that the reactor 100 shown in FIGS. 11 and 12 can be manufactured by a method similar to the method for manufacturing the reactor 100 shown in FIG. 7.

<Configuration of electronic equipment>
FIG. 13 is a partially enlarged schematic diagram of the electronic device according to the first embodiment. The electronic device shown in FIG. 13 has the same configuration as the electronic device shown in FIGS. 11 and 12 and basically shown in FIG. The equipment is different. In the electronic device 200 shown in FIG. 13, the reactor 100 shown in FIGS. 11 and 12 is connected to the substrate 91. The fixing screw 92 is inserted into the through hole 72 of the leg 71 that constitutes the protrusion 66 of the reactor 100 . The tip of the fixing screw 92 is inserted and fixed into a screw hole of the board 91. The height L2 of the leg portion 71 is longer than the distance L3 from the surface of the case 1 to the outer periphery of the winding 41 in the reactor 100.

<Effect>
The case 1, reactor 100, and electronic device 200 described above can provide the same effects as the case 1, reactor 100, and electronic device 200 according to the first embodiment. Further, in the case 1, the protrusion 66 includes a leg 71. The legs 71 protrude outward from the outer shell. The leg portion 71 has a first surface 71a and a second surface 71b. The second surface 71b is located on the opposite side to the first surface 71a. A through hole 72 is formed in the leg portion 71 and extends from the first surface 71a to the second surface 71b.

In this case, the reactor 100 can be fixed to the substrate 91 via the legs 71 by inserting fixing screws 92 or the like into the through holes 72 .

In the case 1, the width L4 of the leg portion 71 in the direction orthogonal to the extending direction of the through hole 72 is 10 mm or more. The diameter D of the through hole 72 is 5 mm or more. In this case, the width L4 of the leg portion 71 can be made sufficiently larger than the diameter D of the through hole 72. As a result, the rigidity of the leg portion 71 can be improved.

The embodiments disclosed this time should be considered to be illustrative in all respects and not restrictive. Unless there is a contradiction, at least two of the embodiments disclosed herein may be combined. The basic scope of the present disclosure is indicated by the claims rather than the above description, and it is intended that all changes within the meaning and range equivalent to the claims are included.

1 Case, 10 First part, 11 Rib part, 12a, 12b, 13a, 13b, 13c, 13d, 21a, 21b, 22a, 22b, 22c, 22d, 31a, 31b, 31c, 31d Connection part, 15, 71 Leg Part, 16 Fixed part, 17 Hole, 20 Second part, 30 Third part, 41 Winding, 51 Gap, 60 Core, 61, 62 Core parts, 65 Central axis, 66 Projection, 67 Winding central axis, 71a 1st surface, 71b 2nd surface, 72 through hole, 91 substrate, 92 fixing screw, 100 reactor, 200 electronic device.

Claims (14)

Equipped with an outer shell that holds the core that makes up the reactor inside,
The core includes a plurality of core components, and further includes:
a rib portion protruding from the inner surface of the outer shell portion and disposed between the plurality of core components ;
The rib portion is in the shape of a convex portion in which an air gap is provided between the adjacent core components,
The outer shell has an annular shape that revolves around a central axis,
The outer shell portion includes a first portion, a second portion, and a third portion,
The rib portions are provided in the first portion and the second portion, respectively,
The first portion and the second portion are connected to overlap each other in a direction along the central axis,
The third portion, the first portion, and the second portion are connected to each other in a direction intersecting the central axis . The side walls of the outer shell portions of the first portion and the second portion are provided continuously in a first, second, and third direction in a direction intersecting the central axis,
The first direction and the second direction are orthogonal to each other, and the second direction and the third direction are orthogonal to each other.
The case according to claim 1, wherein side walls of the outer shell portions of the first portion and the second portion are U-shaped without a curved portion. The case according to claim 1 or 2 , wherein the outer shell portion includes a connection portion that connects the first portion and the second portion with a snap fit. The case according to any one of claims 1 to 3, comprising a protrusion projecting outward from the outer shell. The protrusion is
legs projecting outward from the outer shell;
5. The case according to claim 4, further comprising a fixing part connected to the tip of the leg and extending in a direction different from the direction in which the leg extends. The case according to claim 5, wherein a hole is formed in the fixing part. The case according to claim 5 or 6, wherein the distance between the tip of the leg and the end of the fixing portion opposite to the tip is 15 mm or more. The protrusion includes a leg that protrudes outward from the outer shell and has a first surface and a second surface located on the opposite side of the first surface,
The case according to claim 4, wherein the leg portion is formed with a through hole extending from the first surface to the second surface. The width of the leg in the direction perpendicular to the extending direction of the through hole is 10 mm or more,
The case according to claim 8, wherein the diameter of the through hole is 5 mm or more. The case according to claim 1 or claim 2 ,
the core housed inside the case;
A reactor comprising a winding wire wound around a part of the case. The case includes a projection projecting outward from the outer shell,
The protrusion extends in a direction intersecting a winding center axis around which the winding is wound,
The reactor according to claim 10, wherein the length of the protrusion extending outward from the outer shell is longer than the distance from the surface of the case to the outer periphery of the winding. The reactor according to claim 10,
An electronic device, comprising: a board on which the reactor is mounted. It includes a process of preparing a case, a reactor core, and a winding wire,
The core includes a plurality of core components,
The case is
an outer shell portion that holds the core therein;
a rib portion protruding from the inner surface of the outer shell portion and disposed between the plurality of core components;
The rib portion is in the shape of a convex portion in which an air gap is provided between the adjacent core components.
The outer shell has an annular shape that revolves around a central axis, and further includes:
The outer shell portion includes a first portion, a second portion, and a third portion,
The rib portions are provided in the first portion and the second portion, respectively,
The first part and the second part are connected so as to overlap each other in the direction along the central axis,
The third portion, the first portion, and the second portion are connected to each other in a direction intersecting the central axis,
accommodating the plurality of core components inside the case with the rib portion disposed between the plurality of core components;
A method for manufacturing a reactor, comprising a step of arranging the winding wire so as to wind a part of the case. The side walls of the outer shell portions of the first portion and the second portion are provided continuously in a first, second, and third direction in a direction intersecting the central axis,
The first direction and the second direction are orthogonal to each other, and the second direction and the third direction are orthogonal to each other.
The method for manufacturing a reactor according to claim 13, wherein side walls of the outer shell portions of the first portion and the second portion are U-shaped without a curved portion.

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