Reactor With Asymmetric Inner Interposed Member
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Solution Overview
Problem
The existing reactor designs face challenges in maintaining uniform resin thickness between the winding portion and the inner core portion, leading to potential damage due to vibrations, as the center points of these components can easily displace during resin filling, resulting in non-uniform resin thickness and increased risk of damage.
Innovation Solution
The reactor incorporates an inner interposed member with core holding portions that decenter the core pieces relative to the winding portion, ensuring the resin is filled from a specific displacement direction to maintain uniform thickness and prevent displacement, eliminating the need for additional gap members and enhancing productivity by integrating turns of the winding portion into one piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the center points of the winding portion and inner core portion are aligned during resin filling, then the resin thickness should be uniform, but the center points easily displace during resin filling, resulting in non-uniform resin thickness
Solution Approach 1:
The inner interposed member is designed with an asymmetric structure where the outer circumferential surface is positioned at a first distance from the inner circumferential surface of the winding portion on the displacement direction side, and at a second distance on the opposite side, with the first distance being greater than the second distance. This asymmetric design anticipates and compensates for the expected displacement of the inner core portion during resin filling, ensuring that the resin thickness remains uniform even when the center points shift.
2Manufacturing precision
If additional gap members are added to maintain uniform resin thickness, then manufacturing precision improves, but device complexity and manufacturing time increase
Solution Approach 1:
The functionality of maintaining uniform resin thickness is integrated into the inner interposed member itself, which is already present in the reactor structure as an insulating component. By designing the outer circumferential surface of the inner interposed member with specific asymmetric distances from the winding portion, the patent eliminates the need for separate gap members while achieving uniform resin thickness. This merging of functions reduces device complexity and the number of components.
3Shape
If the inner core portion is held at the center of the winding portion, then structural symmetry is maintained, but resin thickness becomes non-uniform due to displacement during filling
Solution Approach 1:
The inner interposed member is pre-designed with an asymmetric configuration that anticipates the displacement of the inner core portion during resin filling. By positioning the outer circumferential surface at different distances from the winding portion on opposite sides (first distance greater than second distance), the design pre-compensates for the expected shift, counteracting the displacement effect before it compromises resin thickness uniformity.
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 configuration achieves a reactor with reduced resin thickness variation, improved durability against vibrations, and enhanced productivity through simplified manufacturing and integration of resin portions, ensuring consistent magnetic properties and heat dissipation.
Implementation Method 1
the winding portion is filled with the resin from a displacement direction-side position in an opening portion of an end surface of the winding portion in the axial direction of the winding portion, and thus the first assembly is displaced in a direction that is opposite to the displacement direction
Data Source
AI summary
A reactor including: a coil having a winding portion; a magnetic core having a plurality of core pieces; and an inner interposed member interposed between the winding portion and an inner core portion of the magnetic core. An inner resin portion fills an internal space of the winding portion, the inner interposed member includes core holding portions holding the core pieces to be decentered relative to the inner interposed member when seen in the axial direction of the winding portion, a separation distance between the inner circumferential surface of the winding portion and the outer circumferential surface of the inner interposed member on a displacement direction side is longer than a separation distance between the inner circumferential surface of the winding portion and the outer circumferential surface of the inner interposed member on the side that is opposite the displacement direction side.