Embedded Coil Reactor With EE-Core for Higher Inductance
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Solution Overview
Problem
Reactor designs with a coil partially embedded in a holding member struggle to achieve large inductance due to the magnetic path length and cross-section limitations of existing UU-core magnetic cores, making it difficult to enhance inductance effectively.
Innovation Solution
A reactor design featuring a coil with a single winding portion and an EE-core magnetic core, where the magnetic core has a middle leg and outer portions that sandwich the winding portion, combined with a holding member that embeds the coil to ensure insulation and stability, allowing for a shorter magnetic path length and larger cross-section, thereby increasing inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a UU-core magnetic core is used with an eyeglass coil, then the coil turns are prevented from becoming loose, but the magnetic path length becomes long and the cross-section of the magnetic path becomes small, making it difficult to achieve large inductance
Solution Approach 1:
The magnetic core is divided into multiple segments (first magnetic core, second magnetic core, third magnetic core) that are assembled together to form the EE-core structure. This segmentation allows for a shorter magnetic path length and larger cross-section compared to the UU-core, thereby achieving larger inductance while maintaining coil stability through the embedding structure
Solution Approach 2:
The patent transitions from the UU-core configuration to an EE-core configuration, fundamentally changing the spatial arrangement of magnetic paths. The EE-core provides parallel magnetic paths with larger cross-sectional areas and shorter lengths, increasing the overall inductance while the coil remains embedded in the holding member for stability
2Reliability
If the holding member completely covers the side surfaces of the winding portion to ensure insulation, then insulation properties are improved, but the coil becomes unmovable in the horizontal plane requiring complex die holding
Solution Approach 1:
The patent extracts the coil from complete embedding and leaves portions of it exposed. Specifically, the side surfaces of the winding portion are not completely covered by the holding member, allowing the coil to be held by the die during molding without requiring complex constraints, while still providing sufficient insulation where the holding member does cover critical areas
Solution Approach 2:
Instead of completely embedding the coil in the holding member, the patent applies partial embedding where only necessary portions are covered. This partial action provides sufficient insulation for reliability while avoiding the complexity of completely constraining the coil during the molding process
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 design achieves a larger inductance by optimizing the magnetic path length and cross-section, while ensuring insulation and stability of the winding portion, addressing the limitations of previous reactor designs.
Implementation Method 1
reactor comprising a coil, a holding member and a magnetic core
Data Source
AI summary
A reactor includes a coil having a winding part, a holding member, and a magnetic core. The winding part is partially buried inside the holding member, and has an upper exposed part and a lower exposed part exposed from the holding member in the vertical direction (Z direction). The upper exposed part has an upper curved surface part. The upper curved surface part is exposed from the holding member at both sides in the horizontal direction (Y direction). The magnetic core has two outer legs. The winding part is positioned between the two outer legs in the horizontal direction. The holding member has two side walls corresponding to each of the outer legs. Each of the side walls is positioned between the corresponding outer leg and the winding part in the horizontal direction.