Reactor Bobbin Projections Guide Core Insertion
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Solution Overview
Problem
The edges of cores made through green-compact sintering can easily chip during insertion into a bobbin due to perpendicular distal end and side surfaces, leading to contact and potential damage.
Innovation Solution
A reactor design featuring a bobbin with projections on its inner surfaces that contact the core, preventing the edges from chipping by guiding the core during insertion and maintaining contact only with these projections, thus reducing the likelihood of edge contact with the bobbin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a core is punched out with perpendicular distal end and side surfaces, then the core can be easily manufactured, but the edges are easily chipped during insertion into the bobbin
Solution Approach 1:
The patent introduces projections on the inner surface of the bobbin as an intermediary element between the core and the bobbin wall. These projections guide the core during insertion, preventing direct contact between the core edges and the bobbin inner surface, thereby avoiding edge chipping while maintaining the easy manufacturability of perpendicular core surfaces
Solution Approach 2:
The projections are pre-formed on the bobbin before core insertion. This preliminary structuring of the bobbin inner surface creates predetermined contact points that guide the core alignment and prevent edge contact during the insertion process, resolving the contradiction between easy core manufacturing and edge protection
Data Source
AI summary
A reactor includes a bobbin around which a coil is wound, and a core extending through the bobbin. The bobbin has a tubular shape. The core has a quadrangular prism shape. The core includes a distal end surface and a pair of side surfaces perpendicular to the distal end surface. The side surfaces are opposite surfaces of the core. The bobbin includes projections respectively provided on inner surfaces of the bobbin. The inner surfaces of the bobbin respectively face the side surfaces of the core. The projections extend in an axial direction of a tubular portion of the bobbin. The projections are in contact with the core.