Reactor Core Gap Structure for Resin Fill and High Inductance
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Solution Overview
Problem
In reactors with flat end surfaces, it is challenging to fill a sufficient amount of molded resin into the gap portion between core pieces, which affects inductance and heat dissipation, as a narrow gap makes filling difficult while widening it may compromise inductance.
Innovation Solution
A reactor design with a tubular winding portion, E-shaped and T-shaped core portions, and a gap portion between them, where the end surfaces have specific shapes and areas, allowing for high fillability of the molded resin and reduced leakage magnetic flux, enhancing inductance and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the gap portion between core pieces is made narrow, then the inductance is improved, but the fillability of molded resin deteriorates
Solution Approach 1:
The end surface of the first middle core portion is designed with a curved surface instead of a flat surface. This curvature creates a tapered gap structure that facilitates the flow and filling of molded resin while maintaining a narrow effective gap width for high inductance performance
Solution Approach 2:
The curved surface is applied specifically at the end surface of the first middle core portion where it contacts the molded resin, while other portions of the core maintain their original geometry. This localized modification optimizes resin fillability without compromising the overall magnetic circuit integrity
2Ease of manufacture
If the gap portion is widened to increase molded resin filling, then the fillability is improved, but the inductance deteriorates
Solution Approach 1:
The curved end surface creates a gradual transition zone that guides molded resin filling while maintaining a controlled effective gap width. The curvature radius and profile are optimized to ensure sufficient resin penetration without excessive gap width that would reduce inductance
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 design achieves high fillability of the molded resin, resulting in high inductance, low loss, and improved heat dissipation by ensuring proper spreading of the resin and minimizing eddy current losses.
Implementation Method 1
a molded resin portion (4) covering at least a part of the magnetic core (3)
Implementation Method 2
a coil (2) including a tubular winding portion (21)
Implementation Method 3
a magnetic core (3) including a first core portion (3f) and a second core portion (3s) combined in an axial direction
Data Source
AI summary
A reactor is provided with a coil including a winding portion, a magnetic core including an E-shaped first core portion, a T- or E-shaped second core portion and a gap portion, and a molded resin portion. The first core portion is a compact of a composite material including a first middle core portion. The second core portion is a powder compact including a second middle core portion. The gap portion is arranged between an end surface of the first middle core portion and an end surface of the second middle core portion inside the winding portion. The end surface of the first middle core portion has an annular outer end surface, a peripheral surface and an inner end surface. The end surface of the second middle core portion, the outer end surface and the inner end surface are flat surfaces.