Surface-mounted reactor and manufacturing method therefor

A method for fabricating a surface mountable reactor comprising:

• a coil;
• a first magnetic core comprising an axial portion around which the coil is disposed and flange portions at both ends of the axial portion;
• a second magnetic core that is disposed outside the coil to connect the flange portions of the first magnetic core;
• and
• a resin mount disposed outside the coil, wherein
• the second magnetic core comprises a plurality of components separable toward outside the coil,
• a circumference of the coil is surrounded by the second magnetic core and the resin mount, and
• the coil has end portions disposed outside the resin mount,
• the method comprising a first step comprising assembling a first magnetic core, one component for forming a second magnetic core, and another component for forming the second magnetic core, wherein
• the first magnetic core comprises an axial portion around which the coil is disposed and flange portions that are each a plate-shaped member having, at a periphery, two parallel sides and other sides linked to the two parallel sides,
• the one component for forming the second magnetic core has a cross-section comprising:
• an inner linear portion along one of the two parallel sides;
• and an inner curved portion along one of the other sides, wherein the cross-section is perpendicular to a winding axis direction of the coil,
• the another component for forming the second magnetic core has a cross-section comprising:
• an inner linear portion along another of the two parallel sides;
• and an inner curved portion along one of the other sides, wherein the cross-section is perpendicular to the winding axis direction of the coil, and
• the first magnetic core, the one component for forming the second magnetic core, and the another component for forming the second magnetic core are assembled in such a manner that peripheral surfaces of the flange portions of the first magnetic core are brought into contact with an inner surface of the second magnetic core facing the coil.