Reactor Core Holding Structure for Simpler Gap-Controlled Assembly
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Solution Overview
Problem
Conventional reactor configurations face complexity in adjusting the interval between core pieces, requiring jigs or supporting members during assembly, which complicates the production process.
Innovation Solution
A reactor design featuring a holding member with a through hole for the inner core and an outer retraining member that mechanically engages the outer core, allowing for simple positioning and assembly of the inner and outer core parts, enabling high productivity with reduced man-hours and potential resin molding or potting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional configurations are used to couple core pieces together with adhesive or integrate with mold resin, then the reactor can be assembled, but the interval between core pieces must be properly maintained using jigs or supporting members, which complicates the production process
Solution Approach 1:
A resin member is introduced as an intermediary component between the first and second core pieces. This resin member integrates multiple functions: it couples the core pieces together, maintains the predetermined interval between them, and provides structural support. By using this intermediary resin member, the patent eliminates the need for separate jigs or supporting members that would otherwise be required to maintain core piece intervals during assembly, thereby simplifying the production process while ensuring proper spacing.
2Productivity
If core pieces are coupled with adhesive, then the reactor can be assembled, but jigs must be used to maintain the interval until adhesive solidifies, reducing productivity
Solution Approach 1:
The patent merges the functions of adhesive coupling and interval maintenance into a single integrated resin member. This resin member simultaneously performs the bonding function of adhesive and the spacing function of jigs, eliminating the need for separate steps or components. The core pieces are coupled together and the interval is maintained by the same resin member, allowing for faster assembly without requiring waiting periods for adhesive solidification while maintaining proper spacing throughout the process.
3Ease of manufacture
If supporting members are used to maintain core piece interval during resin forming, then the reactor can be assembled, but the supporting members must be removed after resin solidifies, increasing assembly complexity
Solution Approach 1:
The patent extracts the interval-maintaining function from separate supporting members and integrates it directly into the resin member itself. The resin member is designed with a structure that inherently maintains the predetermined interval between core pieces throughout the entire assembly process, from resin forming through solidification. This eliminates the need to introduce and subsequently remove supporting members, as the resin member permanently performs the spacing function as part of its structural design.
Data Source
AI summary
A reactor includes a coil having a wound part, a magnetic core, and a holding member holding an end face of the wound part in an axial direction and the outer core part. The holding member being a frame-shaped body having a through hole into which an end portion of the inner core part in the axial direction is inserted, the outer core part having an inward surface opposing the inner core part, an outward surface on an opposite side to the inward surface, and a plurality of peripheral surfaces joining between the inward surface and the outward surface. The reactor includes an outer retraining member pressing the outer core part against the holding member. The outer retraining member has a pressing piece pressing the outward surface of the outer core part, and an engaging leg piece extending from the pressing piece and having a distal end engaging the holding member.