Asymmetric Core Reactor for High Inductance Low Loss
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Solution Overview
Problem
Conventional reactors have limitations in achieving high inductance with low loss while maintaining a small size, primarily due to inefficiencies in magnetic path area and leakage flux, which result in increased copper and iron losses.
Innovation Solution
The reactor design incorporates chamfered corner portions on the inner core, where outer corner portions are more significantly chamfered than inner corner portions, reducing the magnetic path area and leakage flux, thereby minimizing losses and enhancing inductance without increasing size. This design also includes a resin molded portion for improved strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If corner portions of the magnetic core are evenly rounded, then the magnetic path area is maintained, but inductance is insufficient and loss is high
Solution Approach 1:
The patent applies asymmetry by differentiating the chamfering degree between inner corner portions and outer corner portions of the magnetic core. Specifically, the outer corner portions are chamfered more significantly than the inner corner portions, creating an asymmetric configuration that optimizes the magnetic path. This asymmetric design reduces leakage flux and improves inductance while maintaining acceptable magnetic path area, thereby resolving the contradiction between reducing loss and maintaining reliability.
Solution Approach 2:
The patent applies local quality by applying different chamfering treatments to different locations of the magnetic core. The inner corner portions retain smaller chamfers to preserve magnetic path continuity, while the outer corner portions receive larger chamfers to reduce leakage flux. This localized differentiation allows the magnetic core to have optimal properties in different regions, simultaneously improving inductance and reducing loss.
2Volume of stationary object
If the magnetic core size is reduced to make the reactor smaller, then the reactor size is reduced, but inductance decreases
Solution Approach 1:
The asymmetric chamfering configuration allows for more efficient use of the magnetic path area. By strategically chamfering outer corner portions more than inner corner portions, the design optimizes flux distribution within the available space. This enables the magnetic core to achieve higher inductance density, allowing reactor size reduction while maintaining required inductance levels.
3Reliability
If outer corner portions are significantly chamfered, then leakage flux is reduced and inductance is improved, but magnetic path area decreases
Solution Approach 1:
The patent applies local quality by differentiating the chamfering treatment between inner and outer corner portions. The inner corner portions have smaller chamfers to preserve magnetic path continuity and maintain adequate magnetic path area. The outer corner portions have larger chamfers to effectively reduce leakage flux. This localized differentiation allows the design to achieve improved inductance while minimizing the negative impact on magnetic path area.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The reactor achieves high inductance with low loss and improved strength, as evidenced by simulations, where the chamfered corner design reduces copper and iron losses, allowing for a smaller reactor size while maintaining performance.
Implementation Method 1
a magnetic core including a rectangular parallelepiped inner core portion disposed in each of the winding portions, and outer core portions that are disposed outside the winding portions and are for linking the inner core portions
Data Source
AI summary
Provided is a reactor including a coil provided with two winding portions that are obtained by winding a winding wire such that axes of the winding portions are parallel to each other, and a magnetic core including a rectangular parallelepiped inner core portion disposed in each of the winding portions, and outer core portions that are disposed outside the winding portions and are for linking the inner core portions, in which at least one of two outer corner portions out of four corner portions of each of the inner core portions includes a corner chamfering portion that has been chamfered more than an inner corner portion that is opposite the outer corner portion, the four corner portions facing an inner circumferential surface of the winding portion and the two outer corner portions being disposed on the side of each winding portion that is distant from the other winding portion.