Reactor Core-Coil Molding for Stable Insulation Gap Formation

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Solution Overview

Problem

The existing method for manufacturing reactors for vehicles like hybrid and electric vehicles incurs high costs and decreased productivity due to the need for multiple resin cover types and metal mold types, leading to increased costs and reduced efficiency in mass production.

Innovation Solution

A method involving the assembly of a reactor core with inner-side and outer-side core parts, a tubular coil, and an insulating member, where the core-coil assembly is installed in a mold with the third direction extending upward and downward, allowing for injection molding of the insulating material to fill the gaps between the core and coil, thereby reducing the need for multiple metal mold types and stockpiling of resin covers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple resin cover types and metal mold types are prepared for mass production, then the reactor can be manufactured according to different specifications, but the cost ratio of the metal mold increases and productivity decreases

Engineering Contradiction:

Improveability to manufacture different reactor specificationsVSAvoidmanufacturing cycle time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent applies universality by designing a single standardized metal mold that can produce different types of resin covers through interchangeable or reconfigurable molding inserts. This allows the same base mold structure to manufacture various reactor components (different specifications) without requiring separate dedicated molds for each type, thereby reducing mold inventory and setup time while maintaining production flexibility

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent segments the mold system into a standardized base mold structure and interchangeable molding inserts or cavities. This segmentation allows different resin cover types to be produced by changing only the insert portion while keeping the main mold framework unchanged, enabling quick transition between product types and reducing the need for complete mold replacements

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple resin cover types are stocked for mass production, then different reactor configurations can be assembled, but the inventory cost increases and manufacturing complexity increases

Engineering Contradiction:

Improveability to assemble different reactor configurationsVSAvoidinventory management complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements universality in the resin cover design by creating a standardized base structure that can accommodate different reactor configurations through modular attachments or reconfigurable features. This allows a single resin cover type to serve multiple functions across different reactor specifications, reducing the number of unique cover types that need to be stocked and managed

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If multiple metal mold types are prepared for forming different resin cover types, then various reactor specifications can be produced, but the initial investment cost increases

Engineering Contradiction:

Improveability to produce various reactor specificationsVSAvoidtotal metal mold material required

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges multiple mold functions into a single integrated mold structure by combining different cavities, inserts, or molding zones within one mold assembly. This allows the production of various resin cover types using a consolidated mold system rather than separate individual molds, reducing the total quantity of metal mold material required and simplifying mold management

Inventive Principle:

Principle #5Merging (Combining)

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 stabilizes the formation of gaps between the core and coil, enabling efficient injection molding and reducing the need for multiple metal mold types, thus restraining the decrease in productivity and maintaining cost-effectiveness during mass production.

Implementation Method 1

an injection molding step of injecting insulating material in at least the gap by injection molding

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS12073977B2Method for manufacturing reactor, and reactor

Publication Date: 2024.08.27 KOMATSU LTD

AI summary

A method for manufacturing a reactor includes: assembling a core-coil assembly including a reactor core that includes an inner-side core part extending in a first direction and an outer-side core part extending in a second direction and being linked to the inner-side core part, and a coil disposed around the inner-side core part with a gap therebetween and wound in a tubular shape extending in the first direction, external dimensions of the coil corresponding to external dimensions of the outer-side core part in a third direction; installing the core-coil assembly in a mold in an orientation in which the third direction extends upward and downward so that a lowermost part of the coil in the third direction and a lowermost part of the outer-side core part coincide; and filling at least the gap with an insulation material by injection molding.