MANUFACTURING METHOD FOR REACTOR

PROBLEM TO BE SOLVED: To provide a reactor, particularly a small and light weight reactor suitable for a vehicle and exhibiting excellent cooling effect and environmental resistance. SOLUTION: A plurality of unit coils 1a, 1b, in each of which a covered lead is wound in a hollow flat plate shape, are concentrically superposed, and an air core coil 1 is formed by attaching connection terminal plates 4 to the leads 3 which connect the coil ends of the unit coils mutually and lead out them externally. Plate-shaped wide pre-pregs 6 are inserted at both side surfaces in the stacking direction of the air core coil 1 and between the respective unit coils including terminal portions. These are received in a press female mold 10 provided with a coil molding portion 12, a terminal molding portion 13, and a projecting rib molding portion 14, and a press punch 11 is placed on them and pressure molding is carried out while applying heat to make the resin of the pre-pregs 6 penetrate up to the clearance occurring between the leads of the unit coils to integrally cover the whole while leaving the external connection portions of the connection terminal plates 4 intact. At the same time, a projecting rib 22 is formed on the periphery of a coil housing portion 21. COPYRIGHT: (C)2006,JPO&NCIPI