Reactor Accessory Integration via Composite Core Embedding
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Solution Overview
Problem
The productivity of reactors used in electrically driven vehicles, such as hybrid cars, is hindered by the separate assembly and labor-intensive integration of accessory members like stays and sensor holders, which contribute to the lower efficiency in manufacturing.
Innovation Solution
A reactor design where an accessory member is integrated into the assembly of a coil and magnetic core, with the outer core made of a composite material, embedding a functional portion that protrudes to attach and fix the accessory member, enhancing assembly productivity without compromising magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If accessory members (stay, sensor holder) are prepared separately from the assembly, then the reactor structure is modular and flexible, but the productivity of reactors is reduced due to labor for assembling the accessory member into the assembly
Solution Approach 1:
The accessory member is integrated into the outer core portion by embedding its embedded portion directly into the composite material during the molding process. This merging of the accessory member with the outer core portion eliminates the need for separate assembly operations, thereby resolving the contradiction between modular structure and assembly productivity.
Solution Approach 2:
The accessory member is prepared in advance with an embedded portion that is designed to be embedded into the outer core portion. The resin material is prepared with embedding capability before the actual assembly, allowing the accessory member to be seamlessly integrated during the molding process rather than requiring post-assembly operations.
2Strength
If the outer core portion is made of composite material (soft magnetic powder dispersed in resin), then the accessory member can be embedded and fixed strongly, but the magnetic characteristics may be impaired
Solution Approach 1:
The outer core portion is made of composite material with soft magnetic powder dispersed in resin, creating local variations in material properties. The embedded portion of the accessory member is positioned in areas where the resin matrix provides strong bonding while the soft magnetic powder maintains the necessary magnetic characteristics. This local quality approach allows strong fixation without compromising overall magnetic performance.
Solution Approach 2:
The outer core portion uses a composite material consisting of soft magnetic powder dispersed in a resin matrix. This composite structure combines the magnetic properties of the soft magnetic powder with the embedding and fixation capabilities of the resin. The composite material enables both strong fixation of the accessory member and maintenance of magnetic characteristics, directly resolving the contradiction between strength and magnetic reliability.
3Adaptability or versatility
If accessory members are assembled separately into the assembly, then the assembly process is flexible and adjustable, but the manufacturing time and labor cost increase
Solution Approach 1:
The accessory member assembly process is merged with the outer core portion molding process. The embedded portion of the accessory member is positioned and embedded directly during the resin injection and curing process, combining two separate operations (molding and assembly) into one integrated process. This eliminates the time loss associated with separate assembly operations while maintaining the adaptability to accommodate different accessory member configurations.
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 integration method improves reactor productivity by completing the accessory member arrangement during assembly, ensuring strong fixation and preventing impairment of the composite outer core, while maintaining magnetic performance.
Implementation Method 1
an outer core portion of the magnetic core is made of a composite material obtained by dispersing soft magnetic powder in a resin
Data Source
AI summary
Provided is a reactor in which an accessory member that is attached to the reactor is integrated with an assembly. The reactor includes an assembly of a coil having a winding portion and a magnetic core and an accessory member that is attached to the assembly. In this reactor, an outer core portion of the magnetic core is made of a composite material obtained by dispersing soft magnetic powder in a resin, the outer core portion protruding from the winding portion, and the accessory member includes an embedded portion that is embedded in the outer core portion and a functional portion that protrudes outward from the outer core portion.