# US 12,009,136 B2 · Reactor > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,009,136 B2 - Document ID: US12009136B2 - Status: Granted - Kind: B2 - Application number: 16/977,219 - Filed: 2019-03-01 - Published: 2021-07-01 - Granted: 2024-06-11 - Earliest claimed: 2018-03-02 - Assignees: Autonetworks Technologies, Ltd.; Sumitomo Wiring Systems, Ltd.; Sumitomo Electric Industries, Ltd. - Applicants: AutoNetworks Technologies, Ltd.; Sumitomo Wiring Systems, Ltd.; Sumitomo Electric Industries, Ltd. - Inventors: Kazuhiro Inaba - Web page: https://patentgrep.com/patent/US12009136B2 ## CPC - H01F 27/255: made from particles (H01F27/26 takes precedence) - H01F 1/12: of soft-magnetic materials - H01F 1/26: by macromolecular organic substances - H01F 3/10: Composite arrangements of magnetic circuits - H01F 27/022: {Encapsulation} - H01F 27/263: {Fastening parts of the core together} - H01F 27/306: {Fastening or mounting coils or windings on core, casing or other support} - H01F 27/32: Insulating of coils, windings, or parts thereof - H01F 37/00: Fixed inductances not covered by group H01F17/00 - H01F 41/12: Insulating of windings ({impregnating or encapsulating of transformers H01F41/005} ; of conductors in general H01B13/06) - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES ## Abstract A reactor includes a coil including a winding portion; a magnetic core including an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion; and a resin mold portion that covers at least a portion of an outer circumferential surface of the outer core portion, wherein the outer core portion includes a resin core portion made of a composite material including a soft magnetic powder and a resin, and a first through-hole extending through the resin core portion; and a first end and a second end of the first through-hole open to a surface of the outer core portion other than a coil-facing surface that faces the coil, and the resin mold portion is inserted inside the first through-hole. ## Claims ### Claim 1 A reactor, comprising: a coil including a winding portion; a magnetic core including an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion; and a resin mold portion that covers at least a portion of an outer circumferential surface of the outer core portion, wherein the outer core portion includes: a resin core portion made of a composite material including a soft magnetic powder and a resin; and a first through-hole having a peripheral side completely bound by the outer core portion and extending through the resin core portion, and a first end and a second end of the first through-hole open to a surface of the outer core portion other than a coil-facing surface that faces the coil, and the resin mold portion is inserted inside the first through-hole so as to be completely bound by the outer core portion; and a joining surface where the inner core portion and the outer core portion join together, wherein the inner core portion is made of a composite material including a soft magnetic powder and a resin, and includes a second through-hole that extends in a direction orthogonal to an axial direction of the winding portion through a portion of the inner core portion on the joining surface side, the magnetic core includes a flow path groove for connecting an opening of the first through-hole and an opening of the second through-hole, and the resin mold portion is inserted in the second through-hole via the flow path groove. ### Claim 2 (depends on 1) The reactor according to claim 1, wherein the first through-hole is a linear hole that opens to an upper surface and a lower surface of the outer core portion at the first end and the second end. ### Claim 3 (depends on 1) The reactor according to claim 1, wherein the resin mold portion is formed covering an end portion of the winding portion in an axial direction, and not covering an intermediate portion and exposing the intermediate portion to outside. ### Claim 4 (depends on 1) The reactor according to claim 1, wherein the outer core portion includes: a powder compact molded body including a soft magnetic powder; and the resin core portion covering an outer circumference of the powder compact molded body. ### Claim 5 (depends on 1) The reactor according to claim 1, wherein the composite material has a relative permeability of from 5 to 50. ### Claim 6 (depends on 4) The reactor according to claim 4, wherein the composite material has a relative permeability of from 5 to 50, and the powder compact molded body has a relative permeability that is from 50 to 500, and that is higher than the relative permeability of the composite material. ### Claim 7 (depends on 2) The reactor according to claim 2, wherein the resin mold portion is formed covering an end portion of the winding portion in an axial direction, and not covering an intermediate portion and exposing the intermediate portion to outside. ### Claim 8 (depends on 2) The reactor according to claim 2, wherein the outer core portion includes: a powder compact molded body including a soft magnetic powder; and the resin core portion covering an outer circumference of the powder compact molded body. ### Claim 9 (depends on 3) The reactor according to claim 3, wherein the outer core portion includes: a powder compact molded body including a soft magnetic powder; and the resin core portion covering an outer circumference of the powder compact molded body. ### Claim 10 (depends on 2) The reactor according to claim 2, wherein the composite material has a relative permeability of from 5 to 50. ### Claim 11 (depends on 3) The reactor according to claim 3, wherein the composite material has a relative permeability of from 5 to 50. ### Claim 12 (depends on 4) The reactor according to claim 4, wherein the composite material has a relative permeability of from 5 to 50.