Reactor Magnetic Core Assembly for Crack-Resistant Injection Molding
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Solution Overview
Problem
Existing reactor manufacturing methods using injection molding can cause cracks in magnetic cores due to pressure, especially when high pressure is applied, which affects the shape and integrity of the magnetic core.
Innovation Solution
Incorporating an elastic body within the magnetic core assembly to absorb pressure and distribute load, thereby reducing the likelihood of cracks during the molding process, and using a composite material with soft magnetic powder dispersed in resin for the core pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high pressure is applied during injection molding to form the molded resin portion, then the molding process can be completed efficiently, but cracks are formed in the magnetic core
Solution Approach 1:
A gap member is pre-installed between the core pieces of the magnetic core before injection molding. This gap member acts as a cushioning element that absorbs and distributes the pressure applied during the molding process, preventing direct transmission of high pressure to the magnetic core that would cause cracks, while still allowing the molded resin portion to be formed efficiently
Solution Approach 2:
The gap member serves as an intermediary element between the core pieces and the injected resin. It mediates the pressure transmission by providing a compliant interface that allows pressure distribution without causing damage to the magnetic core structure, enabling both efficient molding and core integrity
2Strength
If the magnetic core is formed as a single integrated piece, then structural integrity is maintained, but adjustment of gap length becomes difficult
Solution Approach 1:
The magnetic core is segmented into multiple core pieces that are combined together with a gap member in between. This segmentation allows the gap length to be adjusted by changing the thickness or positioning of the gap member, while the overall structural integrity is maintained through the combination of core pieces and the resin-impregnated structure
3Productivity
If resin is injected at high pressure to form the molded resin portion, then production speed is improved, but the shape of the magnetic core is distorted
Solution Approach 1:
The gap member is installed beforehand to cushion the impact of high-pressure resin injection. This pre-positioned cushioning element prevents the resin pressure from directly distorting the magnetic core shape, allowing high-speed production to proceed without shape distortion issues
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 elastic body effectively reduces crack formation in the magnetic core, maintaining predetermined inductance and allowing for easier adjustment of gap length, while the composite material enhances magnetic properties and structural integrity.
Implementation Method 1
an elastic body is provided in such a manner as to divide the middle core portion at an intermediate point or divide at least one of boundaries between the middle core portion and the end core portions
Implementation Method 2
at least either the first core piece or the second core piece is constituted by a molded body of a composite material in which a soft magnetic powder is dispersed in a resin
Data Source
AI summary
A reactor is provided in which: a coil includes one winding portion; a magnetic core includes a first core piece and a second core piece combined with each other; at least either the first core piece or the second core piece is constituted by a molded body of a composite material in which a soft magnetic powder is dispersed in a resin; the magnetic core includes a middle core portion, two side core portions, and two end core portions, in a state where the first core piece and the second core piece are combined; the middle core portion includes a portion arranged inside the winding portion; and the elastic body is provided in such a manner as to divide the middle core portion at an intermediate point or divide at least one of boundaries between the middle core portion and the end core portions.