Reactor Core Orientation for Inductance and Burr Clearance
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Solution Overview
Problem
Existing reactor designs require complex and costly die structures to avoid burrs during powder core molding, leading to reduced inductance and increased coil dimensions due to necessary clearances for burr avoidance.
Innovation Solution
A reactor design featuring partial cores with oriented pressed faces, where the first partial core is inserted with its burr directed along the winding axis, eliminating the need for clearance and allowing a simpler die structure, and a second partial core with a flat pressed face orthogonal to the first, ensuring uniform thickness and no step portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the I-shaped core is designed with a small cross-sectional area to provide clearance for burrs, then burr damage to the coil is avoided, but the inductance decreases
Solution Approach 1:
Instead of orienting the pressed face parallel to the winding axis (conventional approach), the patent inverts the orientation so that the pressed face is orthogonal to the winding axis. This inversion causes burrs to extend radially outward away from the coil, eliminating the need for clearance while maintaining large cross-sectional area for high inductance
Solution Approach 2:
The patent converts the harmful effect of burrs (which would damage the coil) into a beneficial configuration by orienting the pressed face orthogonally. The burrs now extend in a direction that naturally clears the coil, transforming the manufacturing defect into a design feature that eliminates the need for clearance
2Reliability
If the U-shaped core is compressed by movable dies in the lengthwise direction to match the I-shaped core orientation, then burr clearance is ensured, but the die structure becomes complicated and expensive
Solution Approach 1:
The patent applies the same orthogonal pressed face orientation to both I-shaped and U-shaped cores. This universal approach allows both core types to be manufactured using identical simple die structures, eliminating the need for complex multi-stage molding while ensuring burr clearance for both core types
Solution Approach 2:
The patent changes the pressing direction parameter from lengthwise (conventional) to transverse (orthogonal to winding axis). This parameter change simplifies the die structure while maintaining effective burr clearance, and the same parameter change is applied to both I-shaped and U-shaped cores for consistency
3Manufacturing precision
If a large hollow core part is designed to ensure clearance with the I-shaped core, then inductance is maintained, but the coil dimension increases
Solution Approach 1:
By inverting the orientation of the pressed face to be orthogonal rather than parallel to the winding axis, the patent eliminates the need for radial clearance between the core and coil. This allows the hollow core part to be minimized while maintaining both inductance and compact coil dimensions
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 design enables a larger cross-sectional area for the first partial core, increasing inductance while simplifying the die structure for press-molding, reducing costs and maintaining high inductance without burr-related clearance requirements.
Implementation Method 1
magnetic powders are poured in a cavity defined by right and left fixed dies and top and bottom movable dies, and the poured magnetic powders are compressed and pressed by the top and bottom movable dies that can move relative to each other, thereby molding a core
Implementation Method 2
a reactor having a core that forms a closed magnetic path... a coil and a core unit including a plurality of partial cores butted one another to form a closed magnetic path
Data Source
AI summary
A method of manufacturing a reactor includes a pair of coils and a pair of core units of partial I-shaped cores with gap members butted together and mounted in the coils. The respective ends of the I-shaped cores are pressed against the ends of a pair of U-shaped cores. The U-shaped cores and the I-shaped cores are formed by pressing powder in movable dies that preheat any burrs formed during pressing to be positioned in a direction different from the winding axis direction to avoid any contact with the coil.