Method of manufacturing reactor

#This application claims priority to Japanese Patent Application No. 2019-073755, filed on Apr. 8, 2019, the entire contents of which are incorporated herein by reference.

#The technology herein disclosed relates to a method of manufacturing a reactor. Specifically, the technology relates to a method of manufacturing a reactor that includes a coil including a wound flat wire, in which the coil has a flat surface and a cooler faces the flat surface.

#A reactor that includes a coil including a flat wire wound into a prism shape, in which the coil has a flat surface, and a cooler faces the flat surface is known. For example, in a reactor of Japanese Patent Application Publication No. 2016-092313, a flat wire that constitutes a coil is covered with an insulating film so as not to be short-circuited to the flat wire adjacent in a pitch direction. Meanwhile, when the flat wire is covered with the insulating film, heat-transfer efficiency from the coil to the cooler decreases. The flat wire on an outer periphery side of the coil is therefore not covered with the insulating film at the flat surface of the coil that faces the cooler.

#FIG. 1 is a perspective view of a reactor manufactured with a manufacturing method according to a first embodiment;

#FIG. 2 is a perspective view of the reactor manufactured with the manufacturing method according to the first embodiment, with a core and a resin cover removed therefrom;

#FIG. 3 is a cross-sectional view taken along a line III-III of FIG. 1;

#Representative, non-limiting examples of the present disclosure will now be described in further detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the disclosure. Furthermore, each of the additional features and teachings disclosed below may be utilized separately or in conjunction with other features and teachings to provide improved methods of manufacturing reactors, as well as methods for using and manufacturing the same.

#Moreover, combinations of features and steps disclosed in the following detailed description may not be necessary to practice the disclosure in the broadest sense, and are instead taught merely to particularly describe representative examples of the disclosure. Furthermore, various features of the above-described and below-described representative examples, as well as the various independent and dependent claims, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings.

#All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter.