JP2011113994A - Reactor, and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To have a structure in which a coil is arranged at a fixed position in a magnetic body region, and can be manufactured by a simple operation and automated by a machine, and can be used for a high withstand voltage application. To provide a reactor that can easily ensure reliability and a method for manufacturing the same.
SOLUTION: Coil cases 2a and 2c enclosing a coil 2b, a magnetic region made of magnetic powder and resin and enclosing the coil case, and a core 2d arranged near the central axis, The gap between 2b and the coil case 2c is filled with resin, and the coil case 2a is provided with a cylindrical hole 2n for drawing out the terminal of the coil 2b, and the upper end of the cylindrical hole 2n and the upper end of the core 2d The part protrudes from the magnetic region. Moreover, it has the connection part 2m which connects the coil case 2c and the center core 2d, they are integrally molded, and a part of connection part 2m is exposed from a magnetic body area | region.
[Selection] Figure 1

Description

  The present invention relates to a reactor and a manufacturing method thereof, and more particularly to a reactor structure suitable for use in a power supply circuit such as a DC-DC converter and an inverter, and a manufacturing method thereof.

  Reactors used in power supply circuits such as DC-DC converters and inverters have conventionally been configured by combining a core and coil obtained by pressing and sintering a magnetic material, and bonding and fixing them. A casting structure is used in which a coil is placed in a case or casting mold in advance, and a mixture of a magnetic powder adjusted to an appropriate viscosity and a resin is poured into it and baked and hardened to form a product. Has come to be. An example of a conventional reactor formed by arranging a coil in a case and injecting a magnetic substance mixture therein is disclosed in Patent Document 1.

  As a structure similar to the casting type, there is an integrally molded surface mount inductor used in a PC or the like that creates a structure by placing magnetic powder around a coil and press sintering. In this case, the mounting terminal portion pulled out from the coil is pulled out in the horizontal direction, and the magnetic body is formed so that the coil is positioned at the center of the core in the mold while protecting the mounting terminal portion by clamping. Thereafter, the mounting terminal portion is bent along the outer periphery of the core to form a terminal surface. An example of an inductor having this structure is shown in Patent Document 2. However, it is difficult to apply the above-mentioned press-sintered structure to a large inductor used at high power, and a cast type structure is more practical for a reactor.

  In the casting type structure, the magnetic material area of the required cross-sectional area must be secured around the coil, so the coil is placed in the casting mold in such a way that it floats in the magnetic material mixture. There is a need. Furthermore, in the case of high current / high voltage applications, for example, a reactor in an inverter power source configuration that drives a motor of a vehicle or the like, the terminal surface of the input / output of the coil is welded directly to the bus bar to perform power processing of several tens of kW. In order to take the structure which does, the shape which protruded the coil terminal surface on the upper surface of a magnetic body area | region is used a lot.

  FIG. 4 is a diagram for explaining an example of the structure and manufacturing method of a casting type reactor manufactured by a conventional technique. FIGS. 4 (a) and 4 (b) are diagrams showing how the casting mold is inserted into the casting mold. FIG. 4C is a perspective view of the step of injecting the magnetic substance mixture, FIG. 4D is a cross-sectional view showing the component arrangement in the casting mold, and FIG. ) Is a perspective view of the completed reactor. First, in order to adjust the height direction in the casting mold, as shown in FIG. 4 (a), the lower part of the coil 1a formed by a rectangular wire is made of the same material or resin as the magnetic material mixture. The produced block 1b is arranged and bonded and fixed to the coil 1a. Next, as shown in FIG. 4 (b), the core 1d for the purpose of reducing the weight of the block adhesive coil 1c with the block 1b bonded to the casting mold 1e and heat dissipation, product fixing, and magnetic substance mixture. Place. Next, as shown in FIG. 4C, in order to position the coil terminals in the horizontal direction, a coil positioning jig 1g is placed on the casting mold 1e. Positioning pins 1h are erected on the casting mold 1e, and the positional relationship between the coil terminals is determined by fitting with a hole provided in the coil positioning jig 1g. After fastening the core 1d and the casting mold 1e with the bolt 1i, the magnetic material mixture 1f adjusted to an appropriate viscosity is poured, and the magnetic material mixture is baked and hardened in a curing furnace. The cross section after pouring the magnetic substance mixture 1f into the casting mold 1e is as shown in FIG. After baking and hardening, the reactor 1j is obtained as shown in FIG. 4 (e) by removing it from the casting mold 1e.

JP 2007-311403 A JP 2006-128473 A

  However, as shown in FIG. 4, a block 1b is formed to determine the position of the coil in the casting mold, and the height of the coil in the magnetic region is determined by installing the block 1b under the coil. In this case, a mold for forming the block 1b is required, and another operation for forming the block 1b is required in the process. The same applies to the case where the material of the block 1b is a resin that does not contain magnetic powder. In addition, a separate process for bonding the molded block 1b to the coil is also required.

  Furthermore, even if the position in the height direction of the coil in the magnetic material region is adjusted by using the block, the horizontal position is not determined, so another tool such as the jig 1g in FIG. 4 is used. It is necessary to measure the dimensions. As a result, a large number of operations increase, and jigs are also required, which is a great obstacle in terms of workability and cost.

  In addition, in a conventional reactor, insulation is ensured by using a wire with a film as a wire constituting the coil. However, with this alone, sufficient reliability can be obtained in applications requiring a high withstand voltage of several kV. There is also a problem that is difficult.

  Accordingly, an object of the present invention is to have a structure in which a coil is arranged at a fixed position in a magnetic material region, and can be easily manufactured and automated by a machine. An object of the present invention is to provide a reactor and a method for manufacturing the same that can ensure reliability even for applications.

  In order to solve the above problems, a reactor according to the present invention includes a coil, a coil case containing the coil, a magnetic region made of magnetic powder and resin, and the vicinity of the central axis of the coil. A gap between the coil and the coil case is filled with resin, and the coil case is provided with a cylindrical hole for drawing out the terminal of the coil, An upper end portion of the cylindrical hole and an upper end portion of the center core protrude from the magnetic region.

  The first method for manufacturing a reactor according to the present invention includes at least two or more joints that connect the coil case and the core, and the coil case, the core, and the joint are integrated with resin. The molded and integrally molded coil case, the core and the joint are placed in a casting mold, and a material made of magnetic powder and resin is injected into the casting mold and then cured. This is a method of manufacturing a reactor for forming the magnetic region, wherein a positioning hole for fitting with the casting mold is formed at the lower end of the core, and at least a part of the joint portion is the It is exposed from the magnetic region.

  Further, in the second method for manufacturing a reactor according to the present invention, the coil case has at least two hook portions for fitting with the core, and a tip portion of the hook portion is formed on an upper portion of the core. A groove to be fitted is provided, and the coil case and the core are installed in the casting mold in a state where the tip portion of the hook portion is fitted to the groove of the core, and the casting mold A method of manufacturing a reactor in which a magnetic material region is formed by injecting a material made of a magnetic powder and a resin and then curing the material, wherein the reactor is positioned at the lower end of the core to be fitted with the casting mold. And at least a part of the hook portion is exposed from the magnetic region.

  Further, a third method for manufacturing a reactor according to the present invention includes: placing the coil case and the core in a casting mold; injecting a material made of magnetic powder and resin into the casting mold; A method of manufacturing a reactor in which the magnetic body region is formed by curing, wherein the coil case has at least two hook portions for fitting with the casting mold, and an upper surface of the casting mold. Is provided with a groove for fitting with a tip portion of the hook portion, and a positioning hole for fitting with the casting mold is formed at a lower end of the core, and at least a part of the hook portion is It is exposed from the magnetic region.

  Here, in the above manufacturing method, at least a part of the exposed hook part or connection part may be cut off after the magnetic body region is cured. Moreover, the positioning hole which fits with the two or more said casting molds may be provided in the lower end of the said center core.

  As described above, in the present invention, by covering the entire coil with the molded coil case, the insulation between the coil and the magnetic body region is ensured, and the gap between the coil and the coil case is filled with resin. The thermal conductivity between the coil and the magnetic material area is secured, and the positional relationship between the coil and the coil case can be determined by making a hole to pull out the coil terminal in the coil case. By providing a hole for positioning with the casting mold, it is possible to position the core in the casting mold.

  In the first manufacturing method of the present invention, the positional relationship between the coil case and the center core is ensured by having the center core integrally connected to the coil case by resin. Considering the strength and weight balance between the coil case and the core, it has at least two joints, and the joint that connects the coil case and the core is disposed so as to be exposed above the upper surface of the magnetic region. It is possible to suppress the deterioration of characteristics due to the interruption of the magnetic path.

  In the second manufacturing method of the present invention, at least two hook portions for fitting the core case with the core are provided in consideration of strength and weight balance, and the tip portion of the hook portion is provided above the core. A groove for fitting is provided, and the positional relationship between the coil case and the core is ensured by fitting both. By disposing the portion connecting the coil case and the core of the hook portion so as to be exposed above the upper surface of the magnetic body region, it is possible to suppress deterioration of characteristics due to interruption of the magnetic path.

  In the third manufacturing method of the present invention, at least two hook portions for fitting the casting mold to the casting mold are provided in consideration of strength and weight balance, and the hook is provided on the upper surface of the casting mold. A groove for fitting with the tip portion of the part is provided, and the positional relationship within the magnetic body region of the coil case is secured by fitting both of them. Arrangement is made so that the part connecting the coil case of the hook part and the casting mold is exposed above the upper surface of the magnetic region, thereby suppressing deterioration of the characteristics due to the interruption of the magnetic path. The hook portion protruding from the region can be cut off.

  As described above, the reactor according to the present invention has a structure in which the periphery of the coil is covered with a coil case formed of resin, so that reliability is ensured even in applications that require a withstand voltage of several kV. I can do it. Also, by filling the gap between the coil and the coil case with thermally conductive epoxy resin or silicon resin, the heat generated by the coil can be transmitted to the magnetic region, and high heat dissipation can be obtained. .

  Moreover, the positional relationship between the coil case and the coil can be determined by opening a hole for pulling out the terminal of the coil in the coil case and pulling out the terminal from the hole. Along with the coil case, the core for the purpose of heat dissipation, product fixing, and weight reduction of the magnetic material and the connecting part that connects them are formed by integral molding with resin, and the position of the casting mold is located on the lower surface of the core Make a hole to decide. By combining these, it becomes possible to determine the positional relationship of the coils in the magnetic body region, and it is possible to ensure the positional accuracy of the terminals.

  In addition, the coil case and the core are molded separately, and a hook portion having an L shape or the like to be fitted to the core is provided in the coil case, and a groove to be fitted is provided at the upper portion of the core. By combining, the positional relationship between the coil case and the core can be determined. Alternatively, a hook part having an L-shape or the like to be fitted to the casting mold is provided in the coil case, and a fitting groove is provided on the upper surface of the casting mold. It is possible to determine the positional relationship of the coil inside, and by separating the hook portion after curing, it is possible to ensure the positional accuracy of the terminal without affecting the outer shape.

  In addition, the portion that connects the coil case of the connecting portion or the hook portion and the core or the casting mold is disposed at a position higher than the upper surface of the magnetic region, so that the connecting portion or the hook portion is located in the magnetic region. It is possible to minimize the blocking of the magnetic path and determine the coil position without causing characteristic deterioration.

  While combining the above coil, coil case, core, connecting part or hook part and placing it in the casting mold, the magnetic substance mixture consisting of the magnetic substance powder and the resin that becomes the magnetic substance region is poured and cured, Thereafter, by removing from the casting mold, it is possible to obtain a reactor capable of positioning the terminal by an easy operation while having both insulating properties and thermal conductivity.

  As described above, the present invention has a structure in which the coil is arranged at a fixed position in the magnetic region, and can be easily manufactured and automated by a machine. Therefore, it is possible to obtain a reactor and a method for manufacturing the same, which can easily ensure reliability for the above-described applications.

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure explaining 1st embodiment of the reactor of 1st embodiment of the reactor by this invention, and the reactor by this invention, Fig.1 (a) is an exploded perspective view of a coil, a coil case, and a center core FIG. 1 (b) is a perspective view in which a coil, a coil case, and a core are assembled, FIG. 1 (c) is a perspective view showing a state before the coil and the casting mold are assembled, and FIG. FIG. 1 (e) is a cross-sectional view after pouring the magnetic substance mixture, and FIG. 1 (f) shows the magnetic substance mixture after pouring the magnetic substance mixture after assembling the coil or the like to the casting mold. The perspective view which shows the reactor removed from the casting mold after hardening. It is a figure explaining 2nd embodiment of the reactor and 2nd embodiment of the reactor by this invention, and Fig.2 (a) is a disassembled perspective view of a coil and a coil case, FIG. FIG. 2B is a perspective view showing the coil and the coil case assembled, FIG. 2C is a perspective view showing the state before the core and the casting mold are assembled, and FIG. FIG. 2 (e) is a cross-sectional view after pouring the magnetic substance mixture, and FIG. 2 (f) is a perspective view showing the reactor removed from the mold after curing. Figure. It is a figure explaining 3rd embodiment of the reactor of 3rd embodiment of the reactor by this invention and the reactor by this invention, Fig.3 (a) is an exploded perspective view of a coil and a coil case, FIG. (B) is a perspective view of the coil and the coil case assembled, FIG. 3 (c) is a perspective view of the core before the casting mold is assembled, and FIG. 3 (d) is an assembly of the coil to the casting mold. FIG. 3E is a cross-sectional view after pouring the magnetic substance mixture, and FIG. 3F is a perspective view showing the reactor removed from the mold after curing. FIG. 3G is a perspective view showing the completed reactor after part of the hook portion is cut away. It is a figure for demonstrating an example of the structure and manufacturing method of the casting type reactor manufactured with a prior art, FIG. 4 (a), FIG.4 (b) is the arrangement | positioning method of components in a casting mold 4 (c) is a perspective view of the step of injecting the magnetic substance mixture, FIG. 4 (d) is a sectional view showing the arrangement of components in the casting mold, and FIG. 4 (e) is completed. The perspective view of a reactor.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a view for explaining a first embodiment of a reactor according to the present invention and a first embodiment of a method for manufacturing a reactor according to the present invention. FIG. 1 (a) is a coil, a coil case, and a core. FIG. 1B is a perspective view in which a coil, a coil case, and a core are assembled. FIG. 1C is a perspective view showing a state before the coil and the casting mold are assembled. (D) is a perspective view showing that a magnetic substance mixture is poured after assembling a coil or the like to a casting mold, FIG. 1 (e) is a cross-sectional view after pouring the magnetic substance mixture, and FIG. It is a perspective view which shows the reactor removed from the casting mold after the magnetic body mixture was hardened.

  As shown in FIG. 1 (a), the coil case 2a of the lid part and the coil case 2c of the container part are covered so as to wrap the coil 2b made of a rectangular wire. The coil case 2c is integrally provided with a core 2d integrally formed with resin and a connecting portion 2m for connecting the coil case 2c and the core 2d. By assembling the coil 2b, the coil case 2a, and the coil case 2c in which the core 2d and the connecting portion 2m are integrated, a coil built-in body 2f having a shape as shown in FIG. 1B is obtained. The gap between the coil 2b and the coil cases 2a and 2c is assembled by being filled with epoxy resin or silicon resin. The coil case 2a is provided with a cylindrical hole 2n through which the terminal 2e of the coil 2b is passed, and the positional relationship between the terminal 2e and the coil cases 2a and 2c is determined by pulling out the terminal 2e therefrom. The upper end portion of the cylindrical hole 2n and the upper end portion of the center core 2d are configured to protrude from the magnetic region after completion.

  Next, as shown in FIG. 1C, the coil built-in body 2f and the casting mold 2g are assembled. Two holes are formed in the lower part of the core 2d formed integrally with the coil case 2c, and are assembled so as to be fitted to the protrusion provided on the bottom of the inner surface of the casting mold 2g. As a result, the positional relationship between the horizontal direction and the height direction of the terminal 2e is determined. As shown in FIG. 1 (d), after assembling the coil built-in body 2f and the casting mold 2g, the core 2d and the casting mold 2g are fastened by the bolt 2i. Thereafter, the magnetic material mixture 2h is poured into the casting mold 2g. The cross-sectional view after pouring is in the state shown in FIG. Of the connecting portion 2m connecting the core 2d and the coil case 2c, the horizontal portion 2j is arranged at a position higher than the liquid level of the magnetic substance mixture 2h. This prevents a reduction in the cross-sectional area of the magnetic path in the magnetic region due to the connecting portion 2m. After curing the magnetic material mixture 2h at an appropriate curing temperature, the reactor 2k shown in FIG. 1 (f) is obtained by removing it from the casting mold 2g.

  FIG. 2 is a view for explaining a second embodiment of a reactor according to the present invention and a second embodiment of a method for manufacturing a reactor according to the present invention. FIG. 2 (a) is an exploded perspective view of a coil and a coil case. Fig. 2 (b) is a perspective view in which a coil and a coil case are assembled. Fig. 2 (c) is a perspective view in which a core and a casting mold are not assembled. FIG. 2 (e) is a cross-sectional view after pouring the magnetic substance mixture, and FIG. 2 (f) is removed from the mold after curing. It is a perspective view which shows a reactor.

  As shown in FIG. 2A, the coil case 3a is covered with the coil case 3a of the lid part and the coil case 3c of the container part so as to wrap the coil 3b. By assembling the coil cases 3a and 3c, a coil built-in body 3p having a shape as shown in FIG. 2B is obtained. The gap between the coil 3b and the coil cases 3a and 3c is filled with epoxy resin or silicon resin and assembled. The coil case 3a is provided with a cylindrical hole 3n through which the terminal 3e of the coil 3b passes, and the positional relationship between the terminal 3e and the coil cases 3a and 3c is determined by pulling out the terminal 3e therefrom. Further, as shown in FIG. 2B, the coil case 3c is provided with four L-shaped hook portions 3d that fit into the core. The upper end portion of the cylindrical hole 3n and the upper end portion of the center core are configured to protrude from the magnetic body region after completion.

  Next, as shown in FIG. 2C, the core 3f and the casting mold 3g are combined. Two holes are formed in the lower part of the center core 3f and assembled so as to be fitted to the casting mold 3g. A groove is provided on the upper portion of the center core 3f so as to be fitted to a tip portion of a hook portion provided in the coil case. Next, as shown in FIG. 2D, the coil built-in body 3p is disposed so that the groove of the core 3f and the tip of the hook portion 3d are fitted in the casting mold 3g, The casting mold 3g is fastened by the bolt 3i. As a result, the positional relationship between the horizontal direction and the height direction of the terminal 3e is determined. Thereafter, the magnetic material mixture 3h is poured into the casting mold 3g. The cross-sectional view after pouring is in the state of FIG. As shown in FIG. 2 (e), the horizontal portion 3j of the hook portion 3d that connects the core 3f and the coil case 3c is arranged to be higher than the liquid level of the magnetic substance mixture 3h. This prevents the hook portion 3d from reducing the cross-sectional area of the magnetic path in the magnetic region. After curing the magnetic material mixture 3h at an appropriate curing temperature, the reactor 3k shown in FIG. 2 (f) is obtained by removing it from the casting mold 3g.

  FIG. 3 is a view for explaining a third embodiment of a reactor according to the present invention and a third embodiment of a method for manufacturing a reactor according to the present invention. FIG. 3 (a) is an exploded perspective view of a coil and a coil case. Fig. 3 (b) is a perspective view of the coil and the coil case assembled, Fig. 3 (c) is a perspective view of the core and the casting mold before assembly, and Fig. 3 (d) is the casting of the coil. FIG. 3E is a cross-sectional view after pouring the magnetic material mixture, and FIG. 3F is a reactor removed from the die after being cured. FIG. 3G is a perspective view showing the completed reactor after a part of the hook portion is cut away.

  As shown in FIG. 3A, the coil 4b is covered with the coil case 4a of the lid portion and the coil case 4c of the container portion. By assembling the coil cases 4a and 4c, a coil built-in body 4p having a shape as shown in FIG. 3B is obtained. The gap between the coil 4b and the coil cases 4a and 4c is filled with epoxy resin or silicon resin and assembled. The coil case 4a is provided with a cylindrical hole 4n through which the terminal 4e of the coil 4b is passed, and the positional relationship between the terminal 4e and the coil cases 4a and 4c is determined by pulling out the terminal 4e therefrom. Further, as shown in FIGS. 3B and 3C, the coil case 4c has three L-shaped hook portions 4d that fit into grooves formed on the upper surface of the casting mold 4g. Is provided. The upper end portion of the cylindrical hole 4n and the upper end portion of the center core 4f are configured to protrude from the magnetic region after completion.

  Next, as shown in FIG. 3C, the core 4f and the casting mold 4g are combined. Two holes are formed in the lower part of the center core 4f and assembled so as to be fitted to the casting mold 4g. A groove is provided in the upper part of the casting mold 4g so as to be fitted to the tip end portion of the hook portion 4d provided in the coil case 4c of FIG.

  Next, as shown in FIG. 3 (d), the coil built-in body 4p is disposed so that the casting mold 4g and the tip of the hook portion 4d are fitted, and the center core 4f is cast by the bolt 4i. Fastened with 4g. Thereby, the positional relationship between the horizontal direction and the height direction of the terminal 4e is determined. Thereafter, the magnetic substance mixture 4h is poured into the casting mold 4g. The cross section after pouring is in the state of FIG. As shown in FIG. 3 (e), the horizontal portion 4j of the hook portion 4d provided on the coil case 4c is arranged to be higher than the liquid level of the magnetic substance mixture 4h. This prevents a reduction in the cross-sectional area of the magnetic path in the magnetic region due to the hook portion 4d. After curing the magnetic material mixture 4h at an appropriate curing temperature, the reactor 4k shown in FIG. 3 (f) is obtained by removing it from the casting mold 4g. In the present embodiment, the completed reactor 4L shown in FIG. 3G is obtained by cutting off the horizontal portion 4j of the hook portion 4d.

  Next, an example of a specific configuration for configuring the reactor of each of the above embodiments will be described. As the coil, a coil obtained by winding a wire of a rectangular wire having a wire width of 9 mm and a thickness of 0.8 mm for 32 turns is used. As the coil case, a coil case is used which is formed by resin molding and has a total insulating layer thickness of 1 mm including the resin filled in the gap around the coil. It is prepared by placing it in a casting mold having a 100 mm square diameter and pouring a metal-based magnetic substance mixture having a permeability of 13. The inductance of the manufactured reactor was 250 μH, the inductance when 190A was energized was 180 μH, and the terminal position accuracy was assured of ± 0.5 mm in both the horizontal and height directions.

  As described above, according to the present invention, the coil is arranged at a fixed position in the magnetic region, and can be manufactured by a simple operation, and the reactor is easy to ensure reliability even for a high withstand voltage application. And the manufacturing method thereof is obtained, and a reactor having high reliability can be provided as a component constituting various large-scale power supplies including those for in-vehicle use.

  It should be noted that the present invention is not limited to the above-described embodiment, and that any design change within a range not departing from the gist of the present invention is included in the present invention. Needless to say, various modifications and corrections are also included in the present invention. For example, the shape, material, etc. of the coil, coil case, magnetic region, core, connection part, and hook part can be changed according to the intended use and performance, the number of connection parts and hook parts, Any structure may be used as long as the shape and number of holes for fitting with the casting mold can be positioned.

1a, 2b, 3b, 4b Coil 1b Block 1c Block adhesive coil 1d, 2d, 3f, 4f Middle core 1e, 2g, 3g, 4g Casting mold 1f, 2h, 3h, 4h Magnetic material mixture 1g Jig 1h Positioning pin 1i 2i, 3i, 4i Bolt 1j, 2k, 3k, 4k, 4L Reactor 2a, 2c, 3a, 3c, 4a, 4c Coil case 2e, 3e, 4e Terminal 2f, 3p, 4p Coil built-in body 2j, 3j, 4j Horizontal Directional part 2m Connection part 2n, 3n, 4n Cylindrical hole
3d, 4d hook part

Claims (6)

  A coil, a coil case enclosing the coil, a magnetic region made of magnetic powder and resin and enclosing the coil case, and a columnar core disposed near the central axis of the coil, The gap between the coil and the coil case is filled with resin, and the coil case is provided with a cylindrical hole for pulling out the terminal of the coil, and the upper end of the cylindrical hole and the upper end of the core The reactor projects from the magnetic region.   The coil case has at least two joints connecting the core and the coil case, the core and the joint are integrally formed of resin, and the integrally formed coil case, the middle A reactor manufacturing method in which a core and the joint are placed in a casting mold, a magnetic powder and a resin material are injected into the casting mold, and then cured to form the magnetic region. The positioning hole for fitting with the casting mold is formed at the lower end of the core, and at least a part of the joint is exposed from the magnetic region. The manufacturing method of the reactor as described in any one of.   The coil case has at least two hook portions for mating with the core, and a groove for mating with the tip portion of the hook portion is provided on the upper portion of the core, and the tip portion of the hook portion The coil case and the core are placed in a casting mold in a state of being fitted with the groove of the core, and a material made of magnetic powder and resin is injected into the casting mold and then cured. In the method of manufacturing a reactor for forming the magnetic body region, a positioning hole for fitting with the casting mold is formed at a lower end of the core, and at least a part of the hook portion is formed. The method for manufacturing a reactor according to claim 1, wherein the reactor is exposed from the magnetic region.   Manufacture of a reactor that forms the magnetic body region by installing the coil case and the core in a casting mold, injecting a material made of magnetic powder and resin into the casting mold, and then curing the material. In the method, the coil case has at least two hook portions for fitting with the casting mold, and a groove for fitting with a tip portion of the hook portion is formed on the upper surface of the casting mold. The positioning hole for fitting with the casting mold is formed at the lower end of the core, and at least a part of the hook portion is exposed from the magnetic body region. The manufacturing method of the reactor as described in any one of.   5. The method of manufacturing a reactor according to claim 4, wherein at least a part of the exposed hook part or the connection part is separated after the magnetic region is cured.   The method for manufacturing a reactor according to any one of claims 2 to 5, wherein a positioning hole for fitting with the two or more casting molds is provided at a lower end of the core. .

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