Reactor Core Alignment via Curved Faces and Gap Plate Projections
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Solution Overview
Problem
In hybrid and fuel cell vehicles, the existing reactor cores with compressed powder magnetic cores experience bond separation due to inclination and misalignment of core members, leading to stress concentration and degradation of noise-vibration performance.
Innovation Solution
A core design featuring convexly curved side faces with gap plates having projections at equal distances from the center, ensuring proper alignment and uniform contact between core members, thereby reducing stress concentration and bond separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If projections are formed at the center of the gap plate to increase adhesive amount, then bond strength between spacer and core member is improved, but core members become misaligned and inclined
Solution Approach 1:
The patent transitions from a single central projection to multiple projections arranged in specific patterns (e.g., four projections at corners or midpoints of sides). This dimensional redistribution of projection locations enables the gap plate to simultaneously achieve adequate adhesive bonding and precise alignment of core members by engaging multiple contact points rather than a single central point.
Solution Approach 2:
Different regions of the gap plate are given different functions through the strategic placement of projections. Corner regions or side midpoint regions are selected based on the specific alignment requirements, creating localized functional zones that optimize both bonding and positioning for different geometric configurations of the core assembly.
2Ease of manufacture
If core members are adhesively-fixed with inclined alignment, then assembly is simpler, but stress concentration occurs and bond separation happens
Solution Approach 1:
The gap plate with strategically positioned projections performs preliminary alignment of core members before the adhesive fully cures. The projections engage with the curved bonding faces to establish correct positioning in advance, preventing inclination during the bonding process and ensuring stress is evenly distributed throughout the adhesive layer rather than concentrated at specific points.
3Ease of manufacture
If curved bonding faces are used on core members, then manufacturing of core members is easier, but uniform contact with flat gap plate is difficult
Solution Approach 1:
Rather than making the entire gap plate surface curved to match the core member faces, the patent applies the curved surface treatment only to localized regions where projections make contact. This selective curvature application maintains ease of core member manufacturing while ensuring uniform contact at the specific projection contact points, resolving the contradiction between manufacturing simplicity and contact uniformity.
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 solution maintains the strength of the bond between core members, prevents degradation of noise-vibration performance, and reduces variation in performance among reactors, while also minimizing manufacturing costs and maintaining heat radiation performance.
Implementation Method 1
a gap plate 16 that is interposed between the curved side faces 15 of the core members 14 and that is bonded to the curved side faces with an adhesive 24
Data Source
AI summary
A core for a reactor includes: a plurality of core members, each of which has a convexly curved side face that serves as a bonding face; and a gap plate that is interposed between the curved side faces of the core members and that is bonded to the curved side faces. The gap plate includes a flat plate and a plurality of projections which project from each face of the plate and each of which has a tip end that contacts the curved side face. The projections are formed at positions near the outer edges of the plate, which are distant from the center of the plate at which no projection is formed, and which are at equal distances from the center of the plate.