# US 2021/0343473 A1 · Reactor and manufacturing method of reactor > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0343473 A1 - Document ID: US20210343473A1 - Status: Published application - Kind: A1 - Application number: 17/181,792 - Filed: 2021-02-22 - Published: 2021-11-04 - Earliest claimed: 2020-04-30 - Assignees: Toyota Jidosha Kabushiki Kaisha - Applicants: Toyota Jidosha Kabushiki Kaisha - Inventors: Kazuki FUNAHASHI; Yasuhiro UENO; Yuki UCHIDA; Naoyuki TAKAHASHI; Yuko MURATA; Takafumi KONDO - Web page: https://patentgrep.com/patent/US20210343473A1 ## CPC - H01F 37/00: Fixed inductances not covered by group H01F17/00 - H01F 41/04: for manufacturing coils {(coils for transformer or inductances H01F27/28)} - B29C 33/14: against the mould wall - B29C 45/14: incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)} - B29C 45/14639: {for obtaining an insulating effect, e.g. for electrical components} - H01F 3/10: Composite arrangements of magnetic circuits - H01F 3/14: Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12) - H01F 27/022: {Encapsulation} - H01F 41/005: {Impregnating or encapsulating (insulating of windings H01F41/12)} - H01F 41/127: {Encapsulating or impregnating (encapsulating coil and core H01F41/005)} - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) ## Abstract A manufacturing method of a reactor includes: a coil mold step of forming a coil mold in which a first resin is molded to cover at least part of a coil; and a main body mold step of forming a main body mold in which a second resin is molded to cover at least part of an assembly body in which the coil, the coil mold, two I-cores, and an O-core surrounding the coil and the coil mold are assembled. In the coil mold step, a gap plate configured to fill a gap between positions where the two I-cores are placed is formed by molding with the first resin. In the main body mold step, gap plates each configured to fill a gap between the O-core and a corresponding one of the I-cores are formed by molding with the second resin. ## Claims ### Claim 1 A manufacturing method of a reactor including a coil, two I-shaped I-cores, and an O-shaped O-core configured to surround the two I-cores, the manufacturing method at least comprising: a coil mold step of forming a coil mold in which a first resin is molded to cover at least part of the coil; and a main body mold step of forming a main body mold in which a second resin is molded to cover at least part of an assembly body in which the coil, the coil mold, the two I-cores, and the O-core surrounding the coil and the coil mold are assembled, the two I-cores being placed inside the coil such that the two I-cores are arranged side by side, wherein: in the coil mold step, a first gap plate configured to fill a gap between positions where the two I-cores are placed is formed by molding with the first resin; and in the main body mold step, second gap plates each configured to fill a gap between the O-core and a corresponding one of the I-cores are formed by molding with the second resin. ### Claim 2 (depends on 1) The manufacturing method according to claim 1, wherein, in the main body mold step, a pin is placed between the O-core and each of the I-cores, and the each of the I-cores is pressed against the first gap plate by the pin. ### Claim 3 (depends on 1) The manufacturing method according to claim 1, wherein: a gap between the two I-cores corresponds to a thickness of the first gap plate in a direction along which the two I-cores are arranged side by side; and a gap between the O-core and each of the I-cores corresponds to a thickness of a corresponding one of the second gap plates in the direction along which the two I-cores are arranged side by side. ### Claim 4 (depends on 1) The manufacturing method according to claim 1, wherein, in the main body mold step, the second resin is injected toward the two I-cores from respective outer sides of the I-cores in a direction along which the I-cores are arranged so that the I-cores are pressed against the first gap plate. ### Claim 5 A reactor comprising: a coil; a coil mold in which a first resin is molded to cover at least part of the coil; two I-shaped I-cores placed inside the coil such that the two I-cores are arranged side by side; an O-shaped O-core configured to surround the coil and the coil mold; and a main body mold configured such that a second resin is molded to cover at least part of an assembly body in which the coil, the coil mold, the two I-cores, and the O-core are assembled, wherein: the coil mold includes a first gap plate formed by molding with the first resin such that the first gap plate fills a gap between the two I-cores; and the main body mold includes second gap plates formed by molding with the second resin such that the second gap plates each fill a gap between the O-core and a corresponding one of the I-cores. ### Claim 6 (depends on 5) The reactor according to claim 5, wherein: the first gap plate is formed integrally with the coil mold; and the second gap plate is formed integrally with the main body mold. ### Claim 7 (depends on 5) The reactor according to claim 5, wherein: a gap between the two I-cores corresponds to a thickness of the first gap plate in a direction along which the two I-cores are arranged side by side; and a gap between the O-core and each of the I-cores corresponds to a thickness of a corresponding one of the second gap plates in the direction along which the two I-cores are arranged side by side. ### Claim 8 (depends on 5) The reactor according to claim 5, wherein the first resin and the second resin contain the same material. ### Claim 9 (depends on 5) The reactor according to claim 5, wherein each of the I-cores is surrounded by the coil mold and the main body mold.