Reactor Core Coupling Structure for Jig-Free Magnetic Core Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional reactor configurations face complexity in adjusting the interval between core pieces, requiring jigs or supporting members until adhesives solidify or resins set, which complicates the production process.
Innovation Solution
A reactor design featuring a holding member and a core coupling member with an engaging leg piece that allows simple mechanical engagement between the inner and outer core parts, enabling easy assembly and positioning without the need for additional support until resin solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If core pieces are coupled with adhesive or integrated with mold resin, then the magnetic core structure is formed, but the interval between core pieces must be properly maintained using jigs or supporting members which complicates the production process
Solution Approach 1:
The magnetic core is divided into multiple core pieces that are coupled together, allowing each piece to be manufactured separately and then assembled. The coupling member is segmented into a holding member and engaging pieces that can be independently positioned and fixed
Solution Approach 2:
The coupling member structure enables self-positioning and self-fixing of core pieces. The engaging pieces with engaging parts automatically locate and secure the core pieces in the correct positions without requiring external jigs or supporting members during assembly
2Manufacturing precision
If core pieces are brought into contact with each other, then the magnetic circuit is formed, but the state in which core pieces come into contact must be precisely adjusted which increases manufacturing complexity
Solution Approach 1:
The coupling member is designed with predetermined geometric features including the holding member with through hole and engaging pieces with specific engaging parts. These pre-designed features automatically ensure proper contact state between core pieces when assembled, eliminating the need for complex adjustment processes
Solution Approach 2:
The invention replaces complex mechanical adjustment systems with a simplified mechanical coupling structure. The engaging pieces directly engage with core pieces through predetermined geometric features, substituting complex adjustment mechanisms with a straightforward engagement system
Data Source
AI summary
A reactor includes a coil, a magnetic core, and a holding member holding an end face of the wound part in an axial direction and an outer core part of the magnetic core. The holding member is a frame-shaped body having a through hole into which an end portion of the inner core part is inserted. The outer core part has an inward surface opposing the inner core part, an outward surface on an opposite side to the inward surface, and a plurality of peripheral surfaces joining between the inward surface and the outward surface. The reactor includes a core coupling member, coupling the outer core part and the inner core part, having a supporting piece supporting the outward surface of the outer core part, and an engaging leg piece having a distal end engaging a peripheral surface engaging part formed on a peripheral surface of the inner core part.