JP5942679B2 - Reactor manufacturing equipment and manufacturing method - Google Patents

Description

  In this specification, the manufacturing apparatus and manufacturing method of the reactor by which the coil is wound around the core are disclosed.

  As described in Patent Document 1, a reactor is known in which a plurality of partial cores are fixed to form a core, and a coil is wound around the core. This type of reactor is easy to manufacture because it can be manufactured by inserting a partial core into a coil formed in advance. In Patent Document 1, a thermosetting resin is used to fix a plurality of partial cores.

  In the technique of Patent Document 1, a coil is formed, a pre-completed reactor is manufactured by assembling a partial core on which a thermosetting resin before curing is applied to a fixed surface to the coil, and the unfinished reactor is heated. And fix the partial cores. That is, an incomplete reactor in which a coil is wound around an incomplete core in which a plurality of partial cores are positioned with a thermosetting resin before thermosetting is manufactured, and the incomplete reactor is put into a heating furnace. To cure the thermosetting resin.

JP 2007-173628 A

In the above technique, the entire unfinished reactor is heated. According to the technique of heating the entire incomplete reactor, it takes time to raise the temperature of the thermosetting resin to the curing temperature. The fixing surface between the partial cores is inside the coil and is shielded by the coil. The fixed surfaces of the partial cores are heated by heating the portion of the core not covered by the coil and transferring the heat. The heat capacity of the core is large, and the thermal conductivity of the material forming the core is low. Therefore, it takes time to raise the temperature of the thermosetting resin to the curing temperature. If the furnace temperature of the heating furnace is raised, the time can be shortened somewhat, but the coil is overheated. The coil is formed of an electric wire whose surface is covered with an insulating film, and the insulating film deteriorates when the coil is overheated. Since it is necessary to prevent overheating of the coil, there is a limit to raising the furnace temperature. In the conventional manufacturing technology, the manufacturing process takes a long time.
In this specification, the technique of shortening the manufacturing process of a reactor is disclosed.

In this specification, the reactor manufacturing apparatus is disclosed. In the reactor, a core is formed from a plurality of partial cores, and a coil is wound around the core. The manufacturing apparatus includes a high frequency heating coil and a power source. In this specification, the coil that forms the reactor is simply called a coil, and the heating coil provided in the manufacturing apparatus is called a high-frequency heating coil.
The high frequency heating coil has a shape for receiving an incomplete reactor in which a coil is wound around an incomplete core in which a plurality of partial cores are positioned. In a state where the incomplete reactor is received in the high-frequency heating coil, the distance between the incomplete core and the high-frequency heating coil is narrow, and the distance between the coil and the high-frequency heating coil is adjusted to be wide. When a high frequency is applied to the high frequency heating coil in a state where an incomplete reactor is received inside the high frequency heating coil, the core and the coil are heated. The heating efficiency of the core and the heating efficiency of the coil vary depending on the frequency of energizing the high-frequency heating coil.
In the manufacturing apparatus disclosed in this specification, the frequency of power supplied from the power source is selected from the following frequency bands. That is, the frequency band satisfying the relationship that the core temperature rise rate is larger than the coil temperature rise rate is selected.

The manufacturing apparatus described above can be applied to an incomplete reactor in which a plurality of partial cores are temporarily fixed and positioned with a thermosetting resin before curing. If the incomplete reactor is inadvertently heated at a high frequency, the coil is overheated before the thermosetting resin is cured. This is because the coil is usually closer to the high-frequency heating coil than the core, and the coil is more easily heated than the core. As a result of research, there is a relationship between the frequency of high-frequency heating, the temperature rise rate of the core, and the temperature rise rate of the coil. By selecting the frequency, the relationship of the temperature rise rate of the core> the temperature rise rate of the coil Was found to be obtained. Contrary to the usual case, it has been found useful to place the core closer to the high frequency heating coil than the coil. In this manufacturing apparatus , the core is positioned closer to the high-frequency heating coil than the coil, and a frequency at which the core is more easily heated than the coil (in other words, the coil is less likely to be heated than the core) is used. According to this manufacturing apparatus , the core in contact with the thermosetting resin to be thermoset can be preferentially heated, and overheating of the coil can be prevented. The time required for thermosetting the thermosetting resin is shortened as compared with the case where the entire unfinished reactor is heated by putting it in the heating furnace.

  Said manufacturing apparatus can also be applied to the incomplete reactor in which resin which fixes partial cores is not given. For example, a coil is wound around a bobbin, and by positioning each of the partial cores with respect to the bobbin, an incomplete core in which a plurality of partial cores are positioned can be obtained. An incomplete reactor in which a coil is wound can be obtained. After obtaining the incomplete reactor, the partial cores can be fixed by filling the gap between the partial cores with a thermoplastic resin in a plastic state and curing. When the partial cores are at room temperature, when filling the gap between the partial cores with the plasticized thermoplastic resin, the fluidity of the plasticized thermoplastic resin is lowered and it is difficult to fill. Preheating the incomplete reactor before filling with the thermosetting resin in the plastic state provides high fluidity of the thermosetting resin in the plastic state, and thermosetting in the plastic state in the gap between the partial cores. Easy to fill with resin. The above manufacturing apparatus can be applied to the preheating stage of an incomplete reactor. The core can be preheated while the coil is not overheated.

  It is preferable that the frequency of the electric power supplied to the high-frequency heating coil is in a band of 1 MHz to 5 MHz. When the frequency is 1 MHz or more, the relationship of the temperature rise rate of the core> the temperature rise rate of the coil is obtained. When the frequency is 5 MHz or more, the insulating film (typically enamel film) covering the surface of the wire forming the coil itself generates heat and deteriorates. When high-frequency heating is performed in a band of 1 MHz to 5 MHz, the core can be preferentially heated while avoiding deterioration of the coil.

In this specification, the manufacturing method of a reactor is also disclosed. In the manufacturing method, an incomplete reactor in which a coil is wound around an incomplete core where a plurality of partial cores are positioned is placed inside the high frequency heating coil, and high frequency power is supplied to the high frequency heating coil. It has a process. The frequency used for the high-frequency heating is selected from a frequency band that satisfies the relationship that the temperature increase rate of the core is larger than the temperature increase rate of the coil. Further , the high frequency heating is performed under the condition that the gap between the unfinished core and the high frequency heating coil is narrow and the gap between the coil and the high frequency heating coil is wide.
As in the case of the manufacturing apparatus, this manufacturing method can be used in the stage of curing the thermosetting resin, or preheats the unfinished reactor in order to fill the thermoplastic resin in a plastic state in a subsequent process. It can also be used in stages.

If an incomplete reactor with a pre-curing thermosetting resin interposed between multiple cores is placed inside the high-frequency heating coil and heated at high frequency, the coil can be prevented from overheating with a short heat treatment. While the thermosetting resin can be cured.
When filling a thermoplastic resin in a later process, if an incomplete reactor with a space between a plurality of partial cores is placed inside the high frequency heating coil and heated at high frequency, the coil is prevented from overheating. The core can be preheated. Later, when the thermoplastic resin plasticized in the space between the plurality of partial cores is filled, it is possible to prevent the viscosity of the plasticized plastic resin from increasing.

The disassembled perspective view of the reactor manufactured with the manufacturing apparatus and manufacturing method of an Example is shown. The perspective view of a manufacturing apparatus is shown. Sectional drawing along the YZ surface of the reactor of Example 1 is shown. Sectional drawing along the YZ surface of the reactor of Example 2 is shown. Sectional drawing along the YZ surface of the reactor of Example 3 is shown. The core temperature and coil temperature in the high frequency heating of the reactor of Example 1 are shown. The core temperature and coil temperature in the conventional high frequency heating are shown. The core temperature and coil temperature when it is put into the heating furnace are shown. The external appearance perspective view of the reactor of Example 1 is shown. Shows the relationship between frequency and iron loss.

The main features of the embodiments shown below are listed.
(Feature 1) A core is formed by fixing a U-shaped first partial iron core and a U-shaped second partial iron core.
(Feature 2) A core is formed by fixing a U-shaped first partial iron core, a first ceramic plate, a U-shaped second partial iron core, and a second ceramic plate in order.
(Feature 3) U-shaped first partial iron core, first ceramic plate, I-shaped first partial intermediate iron core, second ceramic plate, U-shaped second partial iron core, third ceramic plate, and I-shaped second partial middle The core is formed by fixing the iron core and the fourth ceramic plate in order.
(Feature 4) The partial iron core is a sintered body of Fe-Si-Al alloy powder.
(Characteristic 5) The coil of the reactor is a copper wire covered with enamel.
(Feature 6) The thermosetting resin is an epoxy type.
(Feature 7) The curing temperature of the thermosetting resin is lower than the insulation deterioration temperature of the coil.
(Feature 8) The high-frequency heating coil is formed of a pipe, and a cooling medium passes through the pipe.
(Characteristic 9) A frequency satisfying the relationship of “core> coil” is used as the heat generation amount per unit volume and unit time by high frequency heating.
(Feature 10) The core is heated at a high frequency to cure the thermosetting resin in contact with the core.
(Feature 11) The core is heated at high frequency to preheat the core. The gap between the preheated partial cores is filled with a plasticized thermoplastic resin.
(Feature 12) A shielding plate interposed between the high frequency heating coil and the coil is formed inside the high frequency heating coil. By the shielding plate, the contrast phenomenon that the core is easily heated and the coil is not easily heated becomes remarkable. It is possible to energize the high-frequency heating coil with high power while preventing the coil from being overheated. The processing required for curing the thermosetting resin or remaining heat of the core is further shortened.
(Feature 13) A step of measuring the core temperature when the thermosetting resin in contact with the core is cured by high-frequency heating of the core, and a power adjustment step of maintaining the measured core temperature at the curing temperature of the thermosetting resin It has. While maintaining the core temperature at the curing temperature of the thermosetting resin over the curing time of the thermosetting resin, the coil temperature is maintained below the degradation temperature of the insulating material covering the coil. By selecting the positional relationship between the core and the high-frequency heating coil, the positional relationship between the coil and the high-frequency heating coil, the position and size and material of the shielding plate, the material of the core, the material of the coil, etc., the change pattern of the core temperature during high-frequency heating The coil temperature change pattern can be adjusted. By adjusting these parameters, the coil temperature deteriorates the insulating material covering the coil during the period in which the core temperature is maintained at the curing temperature of the thermosetting resin over the curing time of the thermosetting resin. A relationship maintained below the temperature can be obtained. When heated in this relationship, the core can be centrally heated while avoiding deterioration of the insulating properties of the coil, and a high-quality reactor can be manufactured in a short time.

  FIG. 1 shows an exploded perspective view of the reactor 10. The reactor 10 includes a core 50 and a coil 60 wound around the core 50. The core 50 is formed by fixing the first partial core 20, the pair of ceramic plates 30, and the second partial core 40 with a thermosetting resin.

The first partial core 20 includes a pair of protruding sides 22 and 24 and an intermediate side 23 that connects both of them, and the tip surfaces 21 and 25 of the protruding sides 22 and 24 are flat surfaces. A space 26 is secured between the pair of protruding sides 22 and 24, and a U-shape is formed by the pair of protruding sides 22 and 24 and the intermediate side 23. The first partial core 10 is obtained by molding and sintering an Fe—Si—Al alloy powder containing Fe as a main material. The first partial core 10 is a U-shaped iron core and is also a first partial iron core. In this specification, “core” and “iron core” are not distinguished.
The second partial core 40 includes a pair of projecting sides 42 and 44 and an intermediate side 43 connecting the two, and the tip surfaces 41 and 45 of the projecting sides 42 and 44 are flat surfaces. A space 46 is secured between the pair of protruding sides 42 and 44, and a U-shape is formed by the pair of protruding sides 42 and 44 and the intermediate side 43. The fourth partial core 40 is obtained by molding and sintering a powder of an Fe—Si—Al alloy mainly containing Fe. The second partial core 10 is a U-shaped iron core and is also a second partial iron core.

  When the first partial core (U-shaped first partial iron core) 10 and the second partial core (U-shaped second partial iron core) 40 are directly connected, a magnetic saturation phenomenon occurs in the core 50. Therefore, a pair of ceramic plates 30 are interposed between the first partial core 10 and the second partial core 40. That is, the first ceramic plate 31 is interposed between the flat surfaces 21 and 41, and the second ceramic plate 32 is interposed between the flat surfaces 25 and 45. The ceramic plates 31 and 32 are also gap plates that form a gap between the first partial core 10 and the second partial core 40.

  The first ceramic plate 31 is fixed to the flat surface 21, the flat surface 41 is fixed to the first ceramic plate 31, the second ceramic plate 32 is fixed to the flat surface 45, and the flat surface 25 is fixed to the second ceramic plate 32. As a result, an O-shaped core 50 is formed.

  The coil 60 includes a first coil 61 and a second coil 63. The winding start end portion 62 of the first coil 61 is drawn out so as to be connected to another electronic device. The winding end portion 64 of the second coil 63 is also drawn out so that it can be connected to another electronic device. In the drawing, the winding end portion of the first coil 61 and the winding start end portion of the second coil 63 which are hidden in the drawing are connected. The first coil 61 and the second coil 63 which are mechanically divided form one coil 60 electrically.

  At the time of manufacture, the protruding side 42 is inserted from below the space 65 secured in the center of the first coil 61, and the first ceramic plate 31 and the protruding side 22 are inserted from above the space 65. Further, the protruding side 44 is inserted from below the space 66 secured in the center of the second coil 63, and the second ceramic plate 32 and the protruding side 24 are inserted from above the space 66. Between the flat surface 21 and the first ceramic plate 31, between the first ceramic plate 31 and the flat surface 41, between the flat surface 45 and the second ceramic plate 32, and between the second ceramic plate 32 and the flat surface 25, A thermosetting resin before curing is interposed in advance. Thereafter, the thermosetting resin is cured, the first ceramic plate 31 is fixed to the flat surface 21, the flat surface 41 is fixed to the first ceramic plate 31, and the second ceramic plate 32 is fixed to the flat surface 45, The flat surface 25 is fixed to the second ceramic plate 32. Thereafter, the surface covering resin mold 12 described with reference to FIGS. 3 and 9 is formed, whereby the reactor 10 is completed. In FIG. 1, illustration of the surface coating resin mold 12 is omitted.

  When the reactor 10 is completed, the inner side 67 of the first coil 61 and the inner side 68 of the second coil 63 pass through the spaces 26 and 46 secured in the center of the O-shaped core 50. The first coil 61 is wound around the protruding sides 22 and 42, and the second coil 63 is wound around the protruding sides 24 and 44. When the reactor 10 is completed, the first coil 61 and the second coil 63 are wound in the same direction with respect to the magnetic flux passing through the core 50.

  Below, the manufacturing apparatus and manufacturing method of the reactor 10 are demonstrated. In the following, the protruding side 22, the first ceramic plate 31 and the protruding side 42 are inserted into the space 65 secured in the center of the first coil 61, and the protruding side is inserted into the space 66 secured in the center of the second coil 63. The state in which 24, the second ceramic plate 32, and the protruding side 44 are inserted is referred to as an incomplete reactor 10. In the incomplete reactor 10, between the flat surface 21 and the first ceramic plate 31, between the first ceramic plate 31 and the flat surface 41, between the flat surface 45 and the second ceramic plate 32, and between the second ceramic plate 32 and the flat surface. The thermosetting resin is interposed between the flat surface 21 and the first ceramic plate 31, the first ceramic plate 31 and the flat surface 41, the flat surface 45 and the second ceramic plate 32, and the second ceramic plate 32. The flat surface 25 is temporarily fixed with a thermosetting resin. The first partial core 10, the first ceramic plate 31, the second partial core 40, and the second ceramic plate 32 are positioned with respect to the coil 60. In the state of the incomplete reactor 10, since the thermosetting resin is not cured, the fixing strength of the first partial core 10, the first ceramic plate 31, the second partial core 40, and the second ceramic plate 32 is weak. When the thermosetting resin is thermoset, the core 50 is completed.

FIG. 2 shows a state in which the incomplete reactor 10 is set in an apparatus 70 that cures the thermosetting resin by high-frequency heating of the incomplete reactor 10. Reference numeral 72 is a set base for placing and positioning the incomplete reactor 10. It is made of Teflon (registered trademark) with high heat resistance. Reference numeral 78 is a high-frequency heating coil. When the incomplete reactor 10 is set on the set stand 72, the positional relationship is set such that the incomplete reactor 10 is inserted inside the high-frequency heating coil 78. Reference numeral 74 is a shielding plate that enters the gap between the high frequency heating coil 78 and the first coil 61 when the incomplete reactor 10 is inserted inside the high frequency heating coil 78. Reference numeral 76 is a shielding plate that enters the gap between the high-frequency heating coil 78 and the second coil 63 when the incomplete reactor 10 is inserted inside the high-frequency heating coil 78. The shielding plate 74 suppresses the electromagnetic wave radiated from the high frequency heating coil 78 from reaching the first coil 61 and suppresses the first coil 61 from being overheated. The shielding plate 76 suppresses electromagnetic waves radiated from the high-frequency heating coil 78 from reaching the second coil 63 and suppresses the second coil 63 from being overheated.
The shielding plates 74 and 76 are made of a copper plate, and are fixed inside the high-frequency heating coil 78 via a bakelite plate. The shielding plates 74 and 76 are insulated from the high frequency heating coil 78.

  Reference numeral 80 is a pin for pressing the incomplete reactor 10 set on the set base 72 against the set base 72. It is made of Teflon (registered trademark) with high heat resistance. A temperature sensor (not shown) is incorporated at the lower end of the pin. The temperature sensor is pressed against the core 50 and detects the temperature of the core 50. A sensor 82 for detecting the environmental temperature is incorporated at the upper end of the pin 80. In this embodiment, the core temperature around the flat surfaces 21, 25, 41, 45 in contact with the thermosetting resin is corrected by correcting the detection value of the temperature sensor pressed against the core 50 with the detection value of the environmental temperature detection sensor 82. Adopting technology to estimate

  Reference numeral 84 is a high-frequency power source that supplies high-frequency power to the high-frequency heating coil 78. The frequency of the high frequency power supplied to the high frequency heating coil 78 is selected as described later. The high frequency power supply 84 has a function of adjusting the amount of high frequency power. Initially, large power is supplied to rapidly raise the temperature of the core 50. When the core temperature around the flat surfaces 21, 25, 41, 45 estimated as described above approaches the thermosetting temperature of the thermosetting resin, the amount of power supplied is reduced. Thereafter, the core temperature around the flat surfaces 21, 25, 41, 45 is maintained in the vicinity of the thermosetting temperature by adjusting the power supply amount depending on the core temperature. When the thermosetting resin is maintained at the thermosetting temperature only for the time required for thermosetting the resin (thermosetting time), the supply of power is stopped.

  The high-frequency heating coil 78 is manufactured by bending a pipe made of copper, and allows cooling water to pass therethrough. Reference numeral 86 is a cooling water circulation device that cools the high-frequency heating coil 78.

The frequency of the high-frequency power supplied to the high-frequency heating coil 78 is closely related to the calorific value distribution generated in the incomplete reactor 10. FIG. 10 shows the relationship between the frequency and the amount of heat generated in the partial cores (iron cores) 20 and 40. The horizontal axis indicates the frequency, and the vertical axis indicates the iron loss per unit volume. The iron loss is proportional to the calorific value per unit volume / unit time generated in the iron cores 20 and 40. The measurement of FIG. 10 is measured while maintaining the high-frequency electric energy supplied to the high-frequency heating coil 78 at a constant value.
The rhombus in the figure corresponds to the measurement result of the calorific value generated in the iron core of the example, the square corresponds to the measurement result of the calorific value generated in the general-purpose dust core, and the triangle occurs in the ferrite It corresponds to the calorific value measurement result. It is confirmed that the heating efficiency of the iron cores 20 and 40 increases as the frequency increases.

On the other hand, the coil 60 of the reactor 10 uses copper as a main material, and there is no significant relationship between the frequency and the heating efficiency. When the frequency of the high frequency power supplied to the high frequency heating coil 78 is increased, the iron cores 20 and 40 are efficiently heated while the heating efficiency of the coil 60 remains at a low level. In the present embodiment, the frequency is selected from a frequency band (1 MHz to) where a remarkable contrast relationship is obtained that the heating efficiency of the iron cores 20 and 40 is higher than the heating efficiency of the coil 60.
By selecting the frequency, it is possible to obtain a relationship in which the amount of heat generated per unit volume and unit time by high frequency heating is core> coil. Experiments centered on the frequency band can identify a frequency that satisfies the relationship that the temperature rise rate of the partial core is greater than the temperature rise rate of the coil. Furthermore, the frequency satisfying the relationship that the coil temperature while maintaining the core at the curing temperature over the curing time of the thermosetting resin is maintained below the deterioration temperature of the insulating material covering the coil is set. Can be identified.

In the present embodiment, the following three elements achieve the result that the partial cores (iron cores) 20 and 40 are mainly heated and the coil 60 is not overheated.
1) A frequency band in which the heating efficiency of the iron core is significantly higher than the heating efficiency of the coil is selected.
2) The coil is covered with the shielding plates 74 and 76, while the iron cores 20 and 40 are not covered.
3) The interval between the iron cores 20 and 40 and the high frequency heating coil 78 is narrow, and the interval between the coil 60 and the high frequency heating coil 78 is wide.

  FIG. 6 shows the core temperature (curve C1) in the vicinity of the tip surfaces 21, 25, 41, 45, which is generated when the high-frequency heating coil 78 is heated by applying a high frequency of 3.5 Kw and a frequency of 1.75 MHz. And the measurement result of coil temperature (curve C2) is shown. In the above case, since the heating efficiency of the coil 60 is low, there is no need to be afraid of overheating of the coil 60, and a high frequency with sufficient power can be used. Only about 3 minutes after the start of energization, the core temperature in the vicinity of the tip surfaces 21, 25, 41, 45 rises to the thermosetting temperature of the thermosetting resin. In the case of FIG. 6, when the core temperature reaches the curing temperature, the output is adjusted depending on the core temperature, and the core temperature is maintained at the curing temperature. When the thermosetting resin is maintained at the thermosetting temperature (150 ° C. in this embodiment) for only the thermosetting time (3 minutes in this embodiment), the thermosetting resin is completely cured.

  As is apparent from the curve C2, the coil temperature is maintained at a low level until the thermosetting resin is completely cured. The surface of the coil 60 is covered with enamel, and when the temperature is raised to 200 ° C., the insulating property deteriorates. In the case of the example, the coil temperature is maintained at a low level until the thermosetting resin is completely cured, and the insulating property does not deteriorate.

FIG. 7 shows the measurement results of the core temperature (curve C4) and the coil temperature (curve C3) generated when the high-frequency heating coil 78 is heated by energizing a high-frequency wave with an output of 10 Kw and a frequency of 5.0 KHz. Yes. In the case of FIG. 7, although the output is larger than the case of FIG. 6, the increase rate of the curve C4 is slower than the increase rate of the curve C1. It can be seen that more time is required for thermosetting than in the case of FIG. Further, it can be seen that the coil temperature rises to 200 ° C. or higher during the thermosetting process. The coil is overheated, and the insulating properties of the enamel applied to the coil surface are deteriorated. The importance of selecting a frequency from an appropriate frequency band is confirmed.
When the frequency band of the high frequency heating is 1 MHz or more, the core and the thermosetting resin can be heated while preventing overheating of the coil.
When the frequency of the high frequency heating is 5 MHz or more, the insulating film itself covering the surface of the electric wire forming the coil generates heat and deteriorates. When high frequency heating is performed in a band of 1 MHz to 5 MHz, the core and the thermosetting resin can be preferentially heated while avoiding deterioration of the coil.

  FIG. 8 shows a temperature change when an incomplete reactor is put into a heating furnace and thermally cured. In this case, the core temperature and the coil temperature are almost the same. In order to prevent overheating of the coil, the temperature of the furnace cannot be raised too much. Moreover, the fixed surface of the partial cores to which the thermosetting resin before curing is applied is covered with a coil and is not directly exposed to the temperature in the heating furnace. The portion of the core that is not covered by the coil is heated, and the heat is transferred to heat the thermosetting resin. The core has a large heat capacity and is difficult to heat, and the material forming the core has a low thermal conductivity. Therefore, it takes time to raise the temperature of the thermosetting resin to the curing temperature. It takes a long time for the core temperature to rise to the thermosetting temperature. According to the embodiment, as shown in FIG. 6, it can be seen that the reactor can be completed in a much shorter time than the case of FIG.

FIG. 3 shows a cross-sectional view along the yz plane of the completed reactor. Reference numeral 14 denotes a thermoset resin layer, which fixes the first ceramic plate 31 to the first partial core 20, fixes the second partial core 40 to the first ceramic plate 31, and fixes the second partial core 40 to the second partial core 40. This is an adhesive that fixes the ceramic plate 32 and fixes the first partial core 20 to the second ceramic plate 32. Reference numeral 12 is a resin mold that covers the surface of the completed reactor, and protects the reactor 10 from the surrounding environment. Moreover, as shown in FIG. 9, the external shape of the reactor 10 is finished in the shape which is easy to fix to another member. Since the thermal conductivity of the resin is higher than the thermal conductivity of air, the resin mold 12 increases the cooling capacity of the reactor. When a resin mixed with a high thermal conductivity material such as aluminum nitride is used, the heat dissipation capability is further improved. Further, in the reactor, the core vibrates at an alternating frequency applied to the reactor. The resin mold 12 also has a vibration suppressing capability.
The resin mold 12 may be formed of a thermosetting resin or may be formed of a thermoplastic resin.

(Example 2)
FIG. 4 shows a U-shaped first partial iron core 20, a first ceramic plate 23, an I-shaped first partial intermediate iron core 92, a second ceramic plate 24, and a U-shaped second partial iron core 40. In the embodiment, the third ceramic plate 25, the I-shaped second partial intermediate iron core 94, and the fourth ceramic plate 26 are fixed in order. The reactor of this embodiment can also be manufactured by the manufacturing method and the manufacturing apparatus. In the case of Example 2, even if it puts into a heating furnace, the temperature increase rate of the 1st partial intermediate iron core 92 and the 2nd partial intermediate iron core 94 is slow. The benefits of high-frequency heating are even more pronounced.

(Example 3)
In this embodiment, the first partial iron core 20 and the second partial iron core 40 are positioned with respect to the coil 60 using the bobbin of the coil 60. As shown in FIG. 5, the first partial iron core 20 and the second partial iron core 40 are positioned in a positional relationship with a gap G therebetween.
In this embodiment, the reactor is completed by filling the gap G between the first partial iron core 20 and the second partial iron core 40 with a plasticized thermoplastic resin later and curing it. When the first partial iron core 20 and the second partial iron core 40 are at room temperature, plasticization occurs when the plasticized thermoplastic resin is filled in the gap G between the first partial iron core 20 and the second partial iron core 40. Since the fluidity of the thermoplastic resin is reduced, it is difficult to fill. If the first partial iron core 20 and the second partial iron core 40 are preheated before filling with the plasticized thermoplastic resin, the fluidity of the plasticized thermoplastic resin is high, and the first partial iron core 20 It is easy to fill the gap G between the second partial iron core 40 with a plasticized thermoplastic resin. The manufacturing apparatus shown in FIG. 2 can be used for the remaining heat stage of an incomplete reactor. The first partial iron core 20 and the second partial iron core 40 can be preheated while preventing the coil 60 from being overheated.
In the case of the embodiment shown in FIG. 5, the preheated first partial iron core 20, second partial iron core 40, and coil 60 are accommodated in a forming mold, and the plasticized thermoplastic resin is filled in the forming mold. The molding die is shaped to mold the resin mold 12 that covers the surface S of the reactor 10. In that case, the same thermoplastic resin is filled in the gap G between the first partial iron core 20 and the second partial iron core 40 and the formation space of the resin mold 12. The resin layer 16 that fixes the partial cores 20 and 40 and the resin mold 12 that covers the surface of the reactor 10 are formed in the same process. The manufacturing process can be further simplified.

Specific examples of the present invention have been described in detail above, but these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes of the specific examples illustrated above.
The technical elements described in this specification or the drawings exhibit technical usefulness alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technology illustrated in the present specification or the drawings achieves a plurality of objects at the same time, and has technical utility by achieving one of the objects.

10: Reactor 12: Resin mold 14: Hardened layer of thermosetting resin 16: Resin layer cured at the gap between cores 20: First partial core (U-shaped first partial iron core)
30: Ceramic plate 31: First ceramic plate 32: Second ceramic plate 40: Second partial core (U-shaped second partial iron core)
50: Core 60: Coil 70: Manufacturing device 72: Incomplete reactor set base 74: First shielding plate 76: Second shielding plate 80: Incomplete reactor presser pin 82: Temperature sensor 84: Power source 86: Cooling water circulation device 92 : I-shaped first partial intermediate iron core 94: I-shaped second partial intermediate iron core

Claims (5)

A reactor manufacturing apparatus in which a core is formed from a plurality of partial cores and a coil is wound around the core, and includes a high-frequency heating coil and a power source,
The high frequency heating coil has a shape for receiving an incomplete reactor in which a coil is wound around an incomplete core in which a plurality of partial cores are positioned,
With the unfinished reactor received in the high frequency heating coil, the gap between the unfinished core and the high frequency heating coil is narrow, the gap between the coil and the high frequency heating coil is wide,
An apparatus for manufacturing a reactor, wherein a frequency of electric power supplied from a power source is selected from a frequency band satisfying a relationship that a temperature increase rate of a core is larger than a temperature increase rate of a coil.   The reactor manufacturing apparatus according to claim 1, wherein a frequency of power supplied by the power source is selected from a frequency band of 1 to 5 MHz. A method of manufacturing a reactor in which a core is formed from a plurality of partial cores and a coil is wound around the core,
Placing an incomplete reactor in which a coil is wound around an incomplete core in which a plurality of partial cores are positioned inside the high-frequency heating coil;
It has a process of supplying high-frequency power to the high-frequency heating coil,
The frequency is selected from a frequency band that satisfies the relationship that the temperature rise rate of the core is larger than the temperature rise rate of the coil ,
A method for manufacturing a reactor, characterized in that an unfinished reactor is placed inside a high-frequency heating coil, the gap between the unfinished core and the high-frequency heating coil is narrow, and the gap between the coil and the high-frequency heating coil is wide .   4. The method according to claim 3, wherein an incomplete reactor in which a thermosetting resin before curing is interposed between a plurality of partial cores is placed inside the high frequency heating coil. Place an incomplete reactor with a space between the multiple partial cores inside the high-frequency heating coil,
4. The method according to claim 3, further comprising a step of filling a thermoplastic resin in a space between the plurality of partial cores preheated by high frequency heating.

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