# US 12,009,145 B2 · Reactor > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,009,145 B2 - Document ID: US12009145B2 - Status: Granted - Kind: B2 - Application number: 17/286,005 - Filed: 2019-09-27 - Published: 2021-12-16 - Granted: 2024-06-11 - Earliest claimed: 2018-10-18 - 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/US12009145B2 ## CPC - H01F 3/14: Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12) - H01F 27/29: Terminals; Tapping arrangements {for signal inductances} - H01F 27/24: Magnetic cores - H01F 27/255: made from particles (H01F27/26 takes precedence) - H01F 27/263: {Fastening parts of the core together} - H01F 27/324: {Insulation between coil and core, between different winding sections, around the coil; Other insulation structures} - H01F 37/00: Fixed inductances not covered by group H01F17/00 - H01F 41/0246: {Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36)} - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES ## Abstract A reactor includes a coil having a wound portion and a magnetic core. The magnetic core includes a first core piece having a molded body of a composite material and a non-magnetic member, the molded body of the composite material contains a magnetic powder and a resin, the non-magnetic member is held by the molded body of the composite material such that the non-magnetic member and the molded body constitute a single piece, the non-magnetic member includes a base portion arranged along an outer peripheral surface of the molded body of the composite material and a protruding piece protruding from the base portion. The protruding piece is inserted into a region of the molded body of the composite material arranged inside of the wound portion so as to intersect an axial direction of the first core piece. ## Claims ### Claim 1 A reactor comprising: a coil that includes a wound portion; and a magnetic core that is arranged inside of the wound portion and outside of the wound portion, wherein the magnetic core is formed by combining a plurality of core pieces, at least one core piece of the plurality of core pieces is a first core piece that includes a molded body of a composite material and a non-magnetic member, the molded body of the composite material containing a magnetic powder and a resin, the non-magnetic member is held by the molded body of the composite material such that the non-magnetic member and the molded body constitute a single piece, the non-magnetic member includes a base portion that is arranged along an outer peripheral surface of the molded body of the composite material and a protruding piece that protrudes from the base portion, and the protruding piece is inserted into a region of the molded body of the composite material that is arranged inside of the wound portion, such that the protruding piece intersects an axial direction of the first core piece. ### Claim 2 (depends on 1) The reactor according to claim 1, wherein there is a gate mark in an outer peripheral surface of the molded body of the composite material on a protruding end side of the protruding piece. ### Claim 3 (depends on 1) The reactor according to claim 1, wherein the protruding piece protrudes from the base portion by a length that is greater than ½ of a length of the first core piece along a direction orthogonal to the axial direction, and the maximum length of the protruding piece along the axial direction is shorter than 2 mm. ### Claim 4 (depends on 1) The reactor according to claim 1, wherein a protruding direction of the protruding piece is a direction that extends along a long side of an imaginary rectangle that is the minimum rectangle in which an external shape of a cross section of the molded body of the composite material is included, the cross section being taken by cutting the molded body of the composite material along a plane that is orthogonal to the axial direction of the first core piece. ### Claim 5 (depends on 1) The reactor according to claim 1, wherein the coil includes two said wound portions that are adjacent to each other, the magnetic core includes a plurality of the first core pieces that include the protruding pieces that are respectively arranged inside of the two wound portions, and the first core pieces are arranged such that the base portions face each other and the protruding pieces are apart from each other. ### Claim 6 (depends on 1) The reactor according to claim 1, wherein a relative permeability of the molded body of the composite material is at least 5 and no greater than 50, and a relative permeability of a second core piece that is arranged outside of the wound portion is at least two times the relative permeability of the molded body of the composite material. ### Claim 7 (depends on 6) The reactor according to claim 6, wherein the relative permeability of the second core piece is at least 50 and no greater than 500. ### Claim 8 (depends on 1) The reactor according to claim 1, further comprising: a resin molded portion that covers at least a portion of the magnetic core. ### Claim 9 (depends on 2) The reactor according to claim 2, wherein the protruding piece protrudes from the base portion by a length that is greater than ½ of a length of the first core piece along a direction orthogonal to the axial direction, and the maximum length of the protruding piece along the axial direction is shorter than 2 mm. ### Claim 10 (depends on 2) The reactor according to claim 2, wherein a protruding direction of the protruding piece is a direction that extends along a long side of an imaginary rectangle that is the minimum rectangle in which an external shape of a cross section of the molded body of the composite material is included, the cross section being taken by cutting the molded body of the composite material along a plane that is orthogonal to the axial direction of the first core piece. ### Claim 11 (depends on 3) The reactor according to claim 3, wherein a protruding direction of the protruding piece is a direction that extends along a long side of an imaginary rectangle that is the minimum rectangle in which an external shape of a cross section of the molded body of the composite material is included, the cross section being taken by cutting the molded body of the composite material along a plane that is orthogonal to the axial direction of the first core piece. ### Claim 12 (depends on 2) The reactor according to claim 2, wherein the coil includes two said wound portions that are adjacent to each other, the magnetic core includes a plurality of the first core pieces that include the protruding pieces that are respectively arranged inside of the two wound portions, and the first core pieces are arranged such that the base portions face each other and the protruding pieces are apart from each other. ### Claim 13 (depends on 3) The reactor according to claim 3, wherein the coil includes two said wound portions that are adjacent to each other, the magnetic core includes a plurality of the first core pieces that include the protruding pieces that are respectively arranged inside of the two wound portions, and the first core pieces are arranged such that the base portions face each other and the protruding pieces are apart from each other. ### Claim 14 (depends on 4) The reactor according to claim 4, wherein the coil includes two said wound portions that are adjacent to each other, the magnetic core includes a plurality of the first core pieces that include the protruding pieces that are respectively arranged inside of the two wound portions, and the first core pieces are arranged such that the base portions face each other and the protruding pieces are apart from each other. ### Claim 15 (depends on 2) The reactor according to claim 2, wherein a relative permeability of the molded body of the composite material is at least 5 and no greater than 50, and a relative permeability of a second core piece that is arranged outside of the wound portion is at least two times the relative permeability of the molded body of the composite material. ### Claim 16 (depends on 3) The reactor according to claim 3, wherein a relative permeability of the molded body of the composite material is at least 5 and no greater than 50, and a relative permeability of a second core piece that is arranged outside of the wound portion is at least two times the relative permeability of the molded body of the composite material. ### Claim 17 (depends on 4) The reactor according to claim 4, wherein a relative permeability of the molded body of the composite material is at least 5 and no greater than 50, and a relative permeability of a second core piece that is arranged outside of the wound portion is at least two times the relative permeability of the molded body of the composite material. ### Claim 18 (depends on 5) The reactor according to claim 5, wherein a relative permeability of the molded body of the composite material is at least 5 and no greater than 50, and a relative permeability of a second core piece that is arranged outside of the wound portion is at least two times the relative permeability of the molded body of the composite material.