Reactor Magnetic Core Gap Control via Protruding End Surface Member
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Solution Overview
Problem
Existing reactors for in-vehicle DC-DC converters in electric vehicles face instability in magnetic characteristics due to potential air gaps formed during resin molding, which can lead to variations in magnetic properties and mechanical backlash.
Innovation Solution
A reactor design featuring a coil with a winding portion, a magnetic core with inner and outer core portions, and an end surface connecting member with protruding portions that support the outer core, allowing the resin-molded portion to fill the gap between the core portions, thereby minimizing air gaps and ensuring stable magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a gap plate is disposed between the inner core portion and the outer core portion to form a gap, then the magnetic characteristics can be controlled, but insufficient filling of molding resin may occur, leading to unwanted air gaps and unstable magnetic characteristics
Solution Approach 1:
The end surface connecting member acts as an intermediary component between the inner core portion and outer core portion. It provides a structured interface that guides resin flow and ensures proper gap formation through its protruding portions, eliminating the need for separate gap plates while improving manufacturing reliability
Solution Approach 2:
The end surface connecting member is pre-formed with protruding portions that define the gap geometry before resin molding. This preliminary structuring ensures that the resin flows into the correct positions and forms consistent gaps, preventing insufficient filling and air pocket formation during the molding process
2Device complexity
If the outer core portion is directly connected to the end surface connecting member, then structural simplicity is achieved, but air gaps may form between the core portions, causing mechanical backlash and unstable magnetic characteristics
Solution Approach 1:
The end surface connecting member features localized protruding portions at specific positions where gaps are needed. This local differentiation allows the structure to maintain simplicity overall while introducing precise gap control only where required, balancing structural simplicity with magnetic stability
Solution Approach 2:
The protruding portions of the end surface connecting member serve as intermediaries that create and maintain the necessary gaps between core portions. These protrusions act as spacers and guides, ensuring proper spacing and resin distribution without requiring complex additional components
3Strength
If molding resin is used to integrate the outer core portion and end surface connecting member, then mechanical strength is improved, but unwanted air gaps may be formed, leading to variations in magnetic properties
Solution Approach 1:
The end surface connecting member is pre-formed with protruding portions that define the gap geometry before resin molding. This preliminary structuring ensures that the resin flows into the correct positions and forms consistent gaps, preventing insufficient filling and air pocket formation during the molding process
Solution Approach 2:
The protruding portions act as intermediaries that guide resin flow and ensure complete filling of the gap regions. By providing a structured interface, they prevent air entrapment and ensure uniform resin distribution, maintaining both mechanical strength and magnetic uniformity
Data Source
AI summary
Provided is a reactor exhibiting stable magnetic characteristics. The reactor includes a coil, a magnetic core having an inner core portion and an outer core, and an end surface connecting member disposed between an end surface of the winding portion and the outer core portion. The reactor includes a resin-molded portion integrates integrating the outer core portion and the end surface connecting member, and a plurality of protruding portions provided disposed on an outer surface of the end surface connecting member on which the outer core portion is disposed and that supports the outer core portion at a distance from the outer surface, the resin-molded portion enters a gap formed between the outer surface and the outer core portion by the protruding portions, thereby forming a resin gap between the inner core portion and the outer core portion are being separated from each other by the end surface connecting member.