Soft Magnetic Core Member Density Control via Gate Inversion

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Solution Overview

Problem

Current magnetic core components in reactors, particularly those used in hybrid vehicles, face challenges in enhancing heat dissipation and magnetic characteristics, with insufficient techniques for improving these properties.

Innovation Solution

A core member is manufactured by molding a mixture of soft magnetic powder and resin, where specific surfaces, such as installation and interlinkage surfaces, have higher densities than other regions, and the gate is positioned closer to the opposite surface during molding to increase the density of these critical areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the gate is positioned close to the specific inner peripheral surface in the mold, then the filling process is simplified, but the density of the specific portion (installation surface and interlinkage surface) decreases, worsening heat dissipation and magnetic characteristics

Engineering Contradiction:

Improvemolding process simplicityVSAvoidheat dissipation characteristic

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Instead of positioning the gate close to the specific surface (installation surface or interlinkage surface) which would simplify the filling process, the invention inverts this approach by positioning the gate close to the opposite surface. This ensures that the specific surfaces have higher density for better heat dissipation and magnetic characteristics, while the gate trace portion on the opposite surface has lower density which is acceptable since it is not a critical functional surface.

Inventive Principle:

Principle #13The other way round (Inversion)

2Productivity

If the gate is positioned close to the specific inner peripheral surface in the mold, then the injection process is more direct, but the density of the interlinkage surface decreases, worsening magnetic characteristics

Engineering Contradiction:

Improveinjection efficiencyVSAvoidmagnetic characteristic

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention inverts the conventional approach by positioning the gate away from the interlinkage surface (specific surface) and close to the opposite surface. This ensures that the interlinkage surface has high density for excellent magnetic characteristics, while the gate is positioned where its trace will not affect the magnetic performance of the critical surfaces.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If the gate is positioned close to the opposite inner peripheral surface in the mold, then the density of the specific portion increases, but the gate trace portion is located on the opposite surface which may require additional processing

Engineering Contradiction:

Improveheat dissipation characteristicVSAvoidpost-molding processing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention applies local quality by creating different density characteristics in different portions of the core member. The specific surfaces (installation surface and interlinkage surface) have high density for optimal heat dissipation and magnetic characteristics, while the gate trace portion on the opposite surface has lower density. This localized differentiation allows the gate to be positioned optimally without compromising the functional surfaces.

Inventive Principle:

Principle #3Local quality

4Reliability

If the gate is positioned close to the opposite inner peripheral surface in the mold, then the density of the specific portion increases, but the gate trace portion location may affect surface finish on the opposite surface

Engineering Contradiction:

Improvemagnetic characteristicVSAvoidsurface finish quality

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention creates local quality differences where the specific surfaces (installation surface and interlinkage surface) maintain high density and excellent surface finish for their functional requirements, while the gate trace portion is intentionally positioned on the opposite surface where surface finish is less critical. This allows the gate to be positioned optimally for achieving high density in functional areas without compromising the surface quality of critical surfaces.

Inventive Principle:

Principle #3Local quality

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

This approach effectively enhances both the heat dissipation and magnetic characteristics of the core member, leading to improved performance in reactors by optimizing the distribution of soft magnetic powder and resin.

Implementation Method 1

filling a mold with a mixture containing soft magnetic powder and a resin through a gate and solidifying the resin

Methodology Applied

Scientific EffectCuring: Phase Change

Data Source

PatentUS10483029B2Core member, reactor, and method for manufacturing core member

Publication Date: 2019.11.19 AUTONETWORKS TECH LTD

AI summary

A core member capable of favorably meeting required characteristics is provided. A core member according to the present invention is obtained by molding a mixture containing soft magnetic powder and a resin. This core member includes a specific portion including, as a specific surface, at least one of an installation surface facing an object on which the core member is to be installed and an interlinkage surface that is intersected by a magnetic flux excited by a coil, and an opposite surface on a side opposite to the specific surface. The specific portion has a higher density than a region of the opposite surface.