Reactor Core Notch Design for Resin Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing reactor configurations face issues with insufficient resin filling between core pieces, leading to potential noise, contact, and air gaps, which affect the stability and performance of the reactor.
Innovation Solution
The reactor design incorporates notch-shaped resin flow portions at the corners of core pieces, allowing the resin to effectively fill spaces between core pieces and prevent large air gaps, with the option of using powder compacts or composite materials for enhanced magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin is used to fill the inside of the wound portion to simplify manufacturing, then manufacturing process is simplified, but resin cannot sufficiently fill the space between core pieces leading to loose core pieces
Solution Approach 1:
The patent applies preliminary action by forming recess portions on the core pieces before resin injection. These recess portions are pre-designed to guide and facilitate resin flow into the spaces between core pieces, ensuring complete filling before the core pieces can become loose. This preliminary structural modification prevents the worsening of resin filling completeness while maintaining the simplified manufacturing process.
2Ease of manufacture
If gap portions are formed between core pieces using resin, then manufacturing is simplified, but core pieces become loose and may contact each other or the coil causing noise
Solution Approach 1:
The recess portions are formed on core pieces in advance to control resin distribution. This preliminary action ensures that resin properly fills the gap portions and securely bonds core pieces to both the coil and the outer core, preventing core piece loosening and subsequent noise issues while maintaining manufacturing simplicity.
Solution Approach 2:
The patent applies local quality by creating recess portions at specific locations on the core pieces where resin filling is critical. These localized structural modifications concentrate the resin bonding effect at key interfaces (between core pieces and between core pieces and coil), enhancing reliability at critical points without complicating the overall manufacturing process.
3Stability of the object's composition
If resin fills the wound portion to integrate components, then component integration is improved, but resin may not penetrate sufficiently between core pieces
Solution Approach 1:
The recess portions are pre-formed on core pieces to create pathways that guide resin penetration. This preliminary action ensures that when resin is injected to integrate components, it reliably penetrates to the required depth between core pieces, achieving both complete component integration and sufficient penetration depth simultaneously.
Data Source
AI summary
A reactor including a coil having a wound portion that is formed by winding a wire, a magnetic core having an inner core portion disposed inside the wound portion and an outer core portion disposed outside the wound portion, the inner and outer core portions forming a closed magnetic circuit, and an inner resin portion that joins an inner peripheral surface of the wound portion and an outer peripheral surface of the inner core portion to each other. The inner core portion includes a plurality of core pieces and gap portions that are constituted by a portion of the inner resin portion, the core pieces each including a gap-facing surface that faces a corresponding gap portion, a coil-facing surface that faces the inner peripheral surface of the wound portion, and a notch-shaped resin flow portion at a corner portion between the gap-facing surface and the coil-facing surface.