Reactor Bobbin Protrusion Clamping for Injection Molding
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Solution Overview
Problem
In the manufacturing of reactors with a ring core and a bobbin covered by a plastic cover, there is a risk of the edges of the bobbin cylinder portions and the inner circumferential surface of the ring core making contact, leading to stress concentration and potential breakage during high-pressure resin injection.
Innovation Solution
The method involves providing protrusions on the bobbin and the mold to clamp the ring core firmly, preventing the edges of the bobbin from displacing and contacting the ring core, thereby supporting both components and preventing breakage during resin injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the ring core is pressed from both sides within the mold during resin injection, then the resin can be properly injected into the mold, but the edges of the openings of the bobbin cylinder portions and the inner circumferential surface of the ring core are displaced and make contact, causing stress concentration and potential breakage
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the bobbin cylinder portions and the ring core. This resin layer prevents direct contact between the edges of the openings of the bobbin cylinder portions and the inner circumferential surface of the ring core, thereby eliminating stress concentration and preventing breakage while still allowing the ring core to be pressed from both sides during injection molding
2Productivity
If high pressure is applied during resin injection to ensure proper filling, then the mold can be properly filled, but the stress concentrates on the edges of the openings, causing the ring core or bobbin to break
Solution Approach 1:
The resin is introduced beforehand as a cushioning layer between the bobbin and ring core before high-pressure injection occurs. This pre-positioned resin layer acts as a buffer that distributes the injection pressure evenly, preventing stress concentration on the edges of the openings and allowing high-pressure injection to proceed without causing breakage
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 approach ensures that the ring core and bobbin are securely supported, preventing contact and breakage during resin injection, thus ensuring the successful formation of the plastic cover without damaging the reactor components.
Implementation Method 1
injection is carried out in a closed mold by applying pressure on molten resin
Data Source
AI summary
Breakage of a ring core or a bobbin upon injection molding of molten resin is to be prevented in a method of manufacturing a reactor including the ring core. A reactor includes a ring core, a bobbin, a pair of coils, and a plastic cover. The bobbin includes a pair of cylinder portions, and flanges connecting ends of the cylinder portions. The reactor is manufactured by following processes. First protrusions that make contact with an inner circumferential surface of the ring core are provided on outer sides of the flanges along a cylinder axis direction. Second protrusions are provided at positions facing the corresponding first protrusions across the ring core are provided on a cavity surface of a mold that forms the plastic cover by injection molding. The plastic cover is formed by injecting molten resin into the mold while clamping the ring core by the first and second protrusions.