Reactor and manufacturing method for reactor
AssigneesAutonetworks Technologies, Ltd., Sumitomo Wiring Systems, Ltd., Sumitomo Electric Industries, Ltd.
InventorKazuhiro Inaba
Life of this patent
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Abstract
A reactor is provided that can reduce or alleviate stress that can be applied to a magnetic core, and also has excellent manufacturability, and a reactor manufacturing method is also provided. The reactor includes a coil and a magnetic core that includes a plurality of core pieces and a gap member that is interposed between at least one set of core pieces, the magnetic core forming a closed magnetic circuit when the coil becomes excited. At least one gap member is a resin foam gap member that includes, in a contact region that comes into contact with the core pieces, a resin foam portion constituted by resin foam.
Claims8
A reactor comprising:
- a coil;
- and
- a magnetic core that includes a plurality of core pieces and a gap member interposed between at least one set of the core pieces, the magnetic core forming a closed magnetic circuit when the coil becomes excited,
- wherein a constituent material of the core pieces is a composite material containing a soft magnetic powder in an amount of 30 volume percent to 70 volume percent inclusive, a remaining portion being a non-metallic inorganic material in an amount of 20 volume percent or less and a resin, and
- at least one gap member is a resin foam gap member that includes, in a contact region that comes into contact with the core pieces, a resin foam portion constituted by resin foam.
(canceled)
A reactor manufacturing method for manufacturing a reactor by assembling together a coil and a magnetic core that includes a plurality of core pieces, the method comprising:
- a step of preparing the plurality of core pieces constituted by a composite material containing a soft magnetic powder in an amount of 30 volume percent to 70 volume percent inclusive, a remaining portion being a non-metallic inorganic material in an amount of 20 volume percent or less and a resin, and disposing an unfoamed resin sheet between adjacent core pieces among the plurality of core pieces;
- and
- a step of causing the unfoamed resin sheet to foam in a state where a gap between the core pieces between which the unfoamed resin sheets are interposed is restricted according to a predetermined gap length, to form a resin foam portion constituted by resin foam between the core pieces.
Dependencies are inferred from the claim text.