Flexible Fasteners for Reactor Resin Mold Stress Relief
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Solution Overview
Problem
Reactors used in vehicles face stress and potential breakage due to gap changes caused by different linear expansion coefficients of resin and metal materials, leading to stress concentrations and cracks, especially under external impact loads and vibrations.
Innovation Solution
A reactor design incorporating flexible fasteners that deform to absorb gap changes between the resin mold and the supporting member, combined with inflexible fasteners for improved rigidity, to prevent stress propagation and alleviate stress concentrations at the resin mold boundaries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid fasteners are used to secure the resin mold to the supporting member, then the connection strength is improved, but stress concentrations occur at the fastener bases and resin mold boundaries due to gap changes from thermal expansion differences
Solution Approach 1:
The fastener material properties are changed from rigid to flexible, allowing the fastener to deform and absorb thermal expansion gaps between the resin mold and supporting member, thereby preventing stress concentration while maintaining connection strength
Solution Approach 2:
Flexible fasteners with elongated bodies are used instead of rigid fasteners, enabling the fastener to bend and accommodate dimensional changes between dissimilar materials (resin and metal) during thermal cycling, eliminating stress concentration at connection points
2Reliability
If the reactor structure is designed to be robust against vibrations, then the reliability under external impact loads is improved, but the complexity of the fastening system increases to accommodate both thermal and vibrational stresses
Solution Approach 1:
The fastener is designed with flexible material properties and an elongated geometry that simultaneously provides vibration damping and thermal expansion accommodation, achieving dual functionality without increasing system complexity
Solution Approach 2:
The flexible fastener structure serves multiple functions: it absorbs thermal gaps, dampens vibrations, and maintains secure connection, replacing the need for complex rigid fastening systems with simple flexible elements
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 effectively absorbs gap changes and reduces stress concentrations, preventing cracks and breakage of the reactor, enhancing its robustness against thermal and vibrational stresses.
Implementation Method 1
a gap change that occurs between the main body and the case due to different linear expansion coefficients
Implementation Method 2
At least one of the plurality of fasteners is a flexible fastener
Data Source
AI summary
A reactor includes a core made of a magnetic material; a resin mold that encloses the core; a coil that is wound around the core through the resin mold; a plurality of fasteners located on the resin mold; and a supporting member that is secured to the resin mold through the fasteners. At least one of the plurality of fasteners is a flexible fastener.