Reactor Conductive Bar Layout for Cable-Free Lead-Out Reliability
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Solution Overview
Problem
Conventional electrical devices face issues with electric leakage due to damaged cable sheaths and occupy excessive space, leading to increased costs and reduced utilization rates.
Innovation Solution
The design incorporates a reactor with a housing, coil assembly, and a positioning plate with a conductive bar that eliminates the need for cables and crimping terminals, enhancing structural simplicity, reducing costs, and improving electrical connection reliability by using a conductive bar to directly connect with external components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cable and crimping terminal are used to lead out the port, then the electrical connection can be realized, but the risk of electric leakage increases and the device complexity increases
Solution Approach 1:
The patent extracts and removes the cable and crimping terminal from the electrical connection system, replacing them with a conductive bar that is integrally formed with the housing. This eliminates the intermediate components that caused reliability issues and structural complexity, achieving direct electrical connection from the coil assembly to the external component.
Solution Approach 2:
The conductive bar is merged with the housing structure, forming an integrated assembly where the conductive bar serves both as a structural support element and an electrical conductor. This merging eliminates the need for separate cable and terminal components, reducing device complexity while maintaining reliable electrical connection.
2Reliability
If a cable and crimping terminal are used to lead out the port, then the electrical connection can be realized, but the cost of parts and mounting time increases
Solution Approach 1:
By removing the cable and crimping terminal components, the patent eliminates the associated manufacturing and assembly costs. The conductive bar is formed as an integral part of the housing, requiring no additional parts or specialized crimping operations, thereby reducing both material costs and mounting time.
Solution Approach 2:
The housing structure itself serves the dual function of providing mechanical support and electrical conduction through the integrated conductive bar. This self-service approach eliminates the need for separate electrical connection components and their associated assembly operations, reducing manufacturing complexity and cost.
3Reliability
If a cable is used to lead out the port, then the electrical connection can be made, but the space utilization rate inside the case decreases
Solution Approach 1:
The patent removes the cable from the system and replaces it with a rigid conductive bar that is structurally integrated into the housing. This eliminates the need for cable routing space, cable glands, and associated mounting features, thereby increasing the space utilization rate inside the case while maintaining reliable electrical connection.
Data Source
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AI summary
A reactor and an electrical device according to the present application are provided. The reactor includes: a housing, which is provided with a support pillar; a coil assembly, which is fitted in the housing; a positioning plate, which is mounted on the support pillar and is provided with a support surface; and a conductive bar, which is electrically connected with a lead-out end of the coil assembly. The conducting bar has a first section, and a first side portion of the first section is supported on the support surface. With an arrangement of the conducting bar and the positioning plate described above, there is no need to use cables and crimping terminals to lead out the port, which can simplify an overall structural design and reduce cost of parts. The positioning plate shortens a dimension chain from the conducting bar to an external electrical component and avoids error accumulation.