CROSS-REFERENCE TO RELATED APPLICATIONS

This application is the U.S. national stage of PCT/JP2017/021202 filed Jun. 7, 2017, which claims priority of Japanese Patent Application No. JP 2016-116429 filed Jun. 10, 2016 and Japanese Patent Application No. JP 2017-026481 filed Feb. 15, 2017.

TECHNICAL FIELD

The present disclosure relates to a reactor and a method for manufacturing a reactor.

BACKGROUND

JP 2013-128084A discloses a rector including: a coil that includes a winding portion formed by winding a winding wire; and a magnetic core that forms a closed magnetic circuit. The reactor is used as a component of a converter of a hybrid vehicle, for example. The magnetic core can be divided into an inner core portion that is located inside the winding portion, and an outer core portion that is located outside the winding portion. The inner core portion is constituted by a plurality of core pieces that are insulated from each other, and the outer circumferential surface of each core piece and the inner circumferential surface of the winding portion of the coil are insulated from each other by a tubular portion (an inner interposed member) of an insulator.

SUMMARY

A reactor according to the present disclosure includes a coil that includes a winding portion and a magnetic core that includes an inner core portion located inside the winding portion and an outer core portion located outside the winding portion. An inner interposed member is interposed between the inner circumferential surface of the winding portion and the outer circumferential surface of the inner core portion. The inner core portion includes a plurality of core pieces that are separate from each other. The reactor further includes an inner resin portion that fills a gap between the inner circumferential surface of the winding portion and the outer circumferential surface of the inner core portion. The inner interposed member is provided with core holding portions that hold the core pieces at positions that are decentered relative to the inner interposed member when seen in the axial direction of the winding portion. When a direction from the center point of the inner interposed member to the center points of the core pieces seen in the axial direction of the winding portion is defined as a displacement direction, a separation distance between the inner circumferential surfaces of the winding portion and the outer circumferential surface of the inner interposed member on the displacement direction side is longer than a separation distance between the inner circumferential surface of the winding portion and the outer circumferential surface of the inner interposed member on the side that is opposite the displacement direction side.

A reactor manufacturing method according to the present disclosure includes a step of attaching a magnetic core to a coil that includes a winding portion and a step of filling an internal space of the winding portion with resin, wherein the reactor is the reactor according to the present disclosure. A first assembly in which the core pieces are held by the inner interposed member is disposed in the internal space of the winding portion, and the winding portion is filled with the resin from a displacement direction-side position in an opening portion of an end surface of the winding portion in the axial direction of the winding portion, and thus the first assembly is displaced in a direction that is opposite to the displacement direction.

