Reactor Core with Low Elastic Modulus Non-Magnetic Powder
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Solution Overview
Problem
Conventional reactors with copper coils experience thermal expansion, leading to excessive stress on the core, which can cause cracking and failure, and reducing magnetic powder content to lower elastic modulus compromises magnetic characteristics.
Innovation Solution
Incorporating a magnetic-powder resin mixture with non-magnetic powder composed of main component powders with high heat conductivity and low elastic modulus powders into the core, allowing for reduced elastic modulus without decreasing magnetic powder content, thus mitigating stress on the core and maintaining magnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the amount of magnetic powder in the resin mixture is decreased to lower the elastic modulus of the core, then the elastic modulus is reduced, but the magnetic characteristics of the core deteriorate
Solution Approach 1:
The patent applies composite materials by combining magnetic powder, resin, and non-magnetic powder with low elastic modulus in a resin mixture. This composite structure allows the core to achieve both reduced elastic modulus (through the low-modulus non-magnetic powder) and maintained magnetic characteristics (through sufficient magnetic powder content), thereby resolving the contradiction between core flexibility and magnetic performance.
Solution Approach 2:
The patent introduces non-magnetic powder with low elastic modulus as a localized component within the resin mixture. This local quality modification allows specific regions of the core material to have reduced stiffness without compromising the overall magnetic properties, as the magnetic powder remains present in sufficient quantities to maintain magnetic flux generation.
2Reliability
If copper coil is used, then electrical conductivity is improved, but thermal expansion generates excessive stress on the core
Solution Approach 1:
The patent changes the physical parameters of the core material by incorporating non-magnetic powder with low elastic modulus. This parameter modification allows the core to better accommodate thermal expansion of the copper coil, reducing the stress transmitted to the core while maintaining the electrical conductivity benefits of the copper coil.
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 effectively suppresses core damage and breaking while maintaining magnetic characteristics and heat radiation performance, ensuring the reactor's stability and efficiency.
Implementation Method 1
The heat conductivity of the main component powder is larger than that of the resin
Implementation Method 2
The coil is composed of a spirally-wound conductive wire, and generates magnetic field when a current flows therein
Implementation Method 3
An elastic modulus of the low elastic modulus powder is smaller than that of the main component powder
Data Source
AI summary
A reactor is composed of a coil and a core placed in the inside area and outer peripheral area of the coil in a container. The core is composed of magnetic powder, non-magnetic powder, and resin. The non-magnetic powder is composed of main component powder and low elastic modulus powder. The main component powder as a main component of the non-magnetic powder is made of one or more kinds of powder of a heat conductivity which is larger than that of the resin. The low elastic modulus powder is made of one or more kinds of powder of an elastic modulus which is smaller than that of the powder forming the main component powder.