Magnetic Core Coupling Shaft Structure for Reactor Assembly
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Solution Overview
Problem
Existing reactor configurations face challenges in productivity and magnetic properties due to cumbersome assembly processes and the use of bolt members that compromise magnetic performance.
Innovation Solution
A reactor design featuring a magnetic core with a communication hole and a coupling shaft made of composite material, where the composite material is dispersed soft magnetic powder in resin, simplifying assembly and enhancing magnetic properties by eliminating gaps and improving alignment between inner and outer core portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolt members are used to couple core pieces and gap members, then the structural strength and assembly reliability are improved, but the manufacturing complexity and assembly time increase significantly
Solution Approach 1:
The patent merges the coupling function with the magnetic core structure itself by making the coupling shaft an integral part of the magnetic core. The coupling shaft is formed together with the inner core portion and outer core portion through injection molding, eliminating the need for separate bolt members and gap members. This integration reduces the number of parts and assembly steps while maintaining structural strength and magnetic properties.
Solution Approach 2:
The patent uses composite materials consisting of magnetic powder dispersed in resin to manufacture the magnetic core, including the coupling shaft. This composite material approach allows the coupling shaft to possess both mechanical strength for coupling and magnetic properties for flux conduction, eliminating the need for separate metal bolts and magnetic core pieces. The composite material is injected as a liquid or paste and cured to form the integrated structure.
2Strength
If bolt members are arranged to penetrate through all core pieces, then the coupling strength is improved, but the reactor size increases and magnetic properties deteriorate
Solution Approach 1:
The coupling shaft is merged with the magnetic core portions to form an integrated structure. The coupling shaft is not a separate penetrating bolt but is formed together with the inner and outer core portions through injection molding. This integration eliminates air gaps and discontinuities in the magnetic path, improving magnetic properties while maintaining coupling strength through the unified composite material structure.
Solution Approach 2:
The coupling shaft is made of composite material (magnetic powder in resin) that provides both mechanical coupling strength and magnetic flux conduction capability. This eliminates the need for metal bolt members that would create magnetic path discontinuities. The composite material allows the coupling shaft to function both structurally and magnetically within the integrated core structure.
3Adaptability or versatility
If multiple core pieces and gap members are assembled independently, then the manufacturing flexibility is improved, but the assembly complexity and time increase
Solution Approach 1:
The patent merges multiple separate components (inner core portion, outer core portion, coupling shaft) into a single integrated structure manufactured through injection molding. The liquid or paste composite material is injected into a mold cavity that defines the entire magnetic core geometry, including all coupling features. This eliminates the need for separate assembly operations for multiple pieces and gap members, reducing assembly complexity while maintaining manufacturing flexibility through mold design variations.
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
The reactor achieves improved productivity and magnetic performance by ensuring accurate alignment and strong coupling between core portions, reducing magnetic losses and enhancing machinability and adjustability of magnetic properties.
Implementation Method 1
the composite material is obtained by dispersing a soft magnetic powder in a resin
Implementation Method 2
a coupling shaft made of a composite material filled into the communication hole, the coupling shaft coupling the inner core portion and the outer core portion
Data Source
AI summary
A reactor is provided with a coil including a winding portion, and a magnetic core including an inner core portion to be arranged inside the winding portion and an outer core portion to be arranged outside the winding portion. The magnetic core includes a communication hole penetrating through the outer core portion and leading to the inner core portion, and a coupling shaft made of a composite material filled into the communication hole and coupling the inner core portion and the outer core portion. The composite material is obtained by dispersing a soft magnetic powder in a resin.