Coil Molded Article With Integrated Gap For Reactor Inductance Stability
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Solution Overview
Problem
The existing reactor technologies face challenges in maintaining stable inductance due to variable gap lengths between core pieces, which are affected by adhesive thickness and complexity in the bonding process, resulting in poor productivity.
Innovation Solution
A coil molded article with an integrated gap portion on its inner peripheral face, allowing for precise adjustment of gap length and eliminating the need for additional gap members, thereby simplifying the production process and improving reactor productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If core pieces are bonded with adhesive to form magnetic core, then the magnetic core can be assembled, but the gap length becomes unstable due to adhesive thickness variations
Solution Approach 1:
The patent introduces a gap member as an intermediary component between core pieces to define and maintain the gap length. This gap member acts as a precision spacer that mediates the spacing requirement, ensuring stable gap length independent of adhesive thickness variations.
Solution Approach 2:
The gap member is pre-positioned between core pieces before adhesive bonding occurs. This preliminary positioning establishes the correct gap length in advance, so that subsequent adhesive application does not compromise the precision of the gap dimension.
2Ease of manufacture
If multiple core pieces and gap members are bonded together, then the magnetic core can be constructed, but the process becomes complicated reducing productivity
Solution Approach 1:
The patent combines the gap member integration with the core piece bonding process into a single operational step. The gap member is positioned and bonded simultaneously with the core pieces, merging what would otherwise be separate operations into one unified process, thereby simplifying the overall construction procedure and improving productivity.
Data Source
AI summary
Provided is a coil molded article including: a coil having a winding portion; and an integration resin portion that coats at least an inner peripheral face of the winding portion, wherein the coil molded article further includes a gap portion that is integrated into the inner peripheral face and divides an internal space of the winding portion into two portions in an axial direction of the winding portion. Further provided is a reactor including: the above-described coil molded article; and a magnetic core including an inner core portion that is arranged inside the winding portion included in the coil molded article, and an outer core portion that is arranged outside the winding portion.