Reactor Air Discharge Paths for Resin Molding Failures

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Solution Overview

Problem

Conventional reactors experience molding failures such as filling failures and gas burning in the inner resin portions due to gas confinement during the resin molding process, especially when adjacent turns of the coil winding portions are in close contact, preventing gas escape and leading to resin compression and heat generation.

Innovation Solution

Incorporating air discharge paths in the inner interposed members that extend along the axial direction of the winding portions to guide and discharge gas from the resin flow paths, reducing the likelihood of gas confinement and compression during resin injection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If resin is filled into resin flow paths from end face sides of winding portions to form inner resin portions, then the inner resin portions can be molded, but gas is confined in the resin flow paths causing molding failures such as filling failures and gas burning

Engineering Contradiction:

Improvemolding quality of inner resin portionsVSAvoidmolding process reliability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Air discharge paths are formed in the spacers before the resin molding process to provide predetermined gas escape routes. This preliminary preparation of discharge paths prevents gas confinement during resin filling, eliminating molding failures while maintaining the integrity of the inner resin portions.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The air discharge paths act as intermediary channels between the resin flow paths and the external environment. These paths provide a dedicated route for gas to escape during resin injection, mediating between the conflicting requirements of filling the resin flow paths completely and allowing gas to escape freely.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If adjacent turns of coil winding portions are in close contact, then the reactor structure is compact, but gas escape is prevented leading to resin compression and heat generation

Engineering Contradiction:

Improvereactor sizeVSAvoidtemperature during molding

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The air discharge paths serve as intermediary escape routes that allow gas to leave the resin flow paths even when the coil winding portions are in close contact. This prevents gas compression and the associated heat generation, maintaining safe temperatures during the molding process while preserving the compact reactor structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10600557B2Reactor having air discharge paths

Publication Date: 2020.03.24 AUTONETWORKS TECH LTD

AI summary

Provided is a reactor in which it is possible to reduce molding failures in inner resin portions when molding the inner resin portions. A reactor includes: a coil having winding portions; and a magnetic core having inner core portions and outer core portions. The reactor further includes: inner resin portions that fill gaps between the winding portions and the inner core portions; and inner interposed members that are interposed between the winding portions and the inner core portions, and form resin flow paths. The inner interposed members have spacers arranged between the winding portions and the inner core portions. The spacers are provided with air discharge paths that are in communication with the resin flow paths, and extend in the axial direction of the winding portions to at least one end face side of the winding portions.