Molded Reactor Core Structure for Strong Resin Adhesion
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Solution Overview
Problem
The adhesive properties between the outer core portion and the resin mold portion in existing reactors are often insufficient, leading to potential separation and increased reactor size when attempting to enhance adhesion by thickening the resin mold portion.
Innovation Solution
A reactor design featuring a resin core portion made of a composite material with a soft magnetic powder and resin, including a first through-hole that allows the resin mold portion to be inserted, providing mechanical engagement and enhancing adhesion without increasing the reactor's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resin mold portion is formed thicker to improve adhesion, then the adhesive properties between the outer core portion and resin mold portion are improved, but the reactor size is increased
Solution Approach 1:
The resin mold portion is inserted into a through-hole formed in the outer core portion, creating a nested structure where the resin mold portion is positioned within the outer core portion. This nesting approach provides mechanical interlocking and enhances adhesion without requiring the resin mold portion to be thicker, thereby maintaining compact reactor dimensions while improving reliability of the connection between components
Solution Approach 2:
Instead of increasing adhesion by increasing the thickness (one dimension) of the resin mold portion, the invention utilizes the through-hole dimension to create a three-dimensional interlocking structure. The resin mold portion extends through the outer core portion, providing adhesion enhancement in multiple spatial dimensions rather than relying solely on increased thickness, thus avoiding reactor size increase
2Volume of moving object
If the resin mold portion is formed thinner to reduce reactor size, then the reactor size is reduced, but the adhesive properties between the outer core portion and resin mold portion deteriorate
Solution Approach 1:
The resin mold portion is inserted into a through-hole formed in the outer core portion, creating a nested structure where the resin mold portion is positioned within the outer core portion. This nesting approach provides mechanical interlocking and enhances adhesion without requiring the resin mold portion to be thicker, thereby maintaining compact reactor dimensions while improving reliability of the connection between components
Solution Approach 2:
The outer core portion is constructed as a composite structure including a soft magnetic powder core and a resin component. This composite material approach allows the outer core portion to provide both magnetic functionality and structural support for the through-hole, enabling the thin resin mold portion to achieve sufficient adhesion through the interlocking mechanism rather than relying on material thickness alone
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 ensures a firm integral formation of the reactor without size increase, suppresses resin mold separation, and reduces magnetic flux leakage by optimizing relative permeability and heat dissipation.
Implementation Method 1
a first through-hole extending through the resin core portion, and a first end and a second end of the first through-hole open to a surface of the outer core portion other than a coil-facing surface that faces the coil, and the resin mold portion is inserted inside the first through-hole
Data Source
AI summary
A reactor includes a coil including a winding portion; a magnetic core including an inner core portion disposed inside the winding portion and an outer core portion disposed outside the winding portion; and a resin mold portion that covers at least a portion of an outer circumferential surface of the outer core portion, wherein the outer core portion includes a resin core portion made of a composite material including a soft magnetic powder and a resin, and a first through-hole extending through the resin core portion; and a first end and a second end of the first through-hole open to a surface of the outer core portion other than a coil-facing surface that faces the coil, and the resin mold portion is inserted inside the first through-hole.