Reactor Core Projections for Compact Winding Positioning

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Solution Overview

Problem

Conventional reactors face challenges in reducing size due to large clearances between wound portions and inner core portions, which are necessary to prevent magnetic flux leakage and ensure mechanical strength, making it difficult to miniaturize the device.

Innovation Solution

A reactor design using a magnetic core with composite material molded bodies and projections on the inner core portions to position the wound portions radially, eliminating the need for additional interposed members and allowing for smaller clearances, achieved through resin molding techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If inner interposed members are used to position wound portions and inner core portions, then mechanical strength and insulation are ensured, but the clearance size increases making reactor miniaturization difficult

Engineering Contradiction:

Improvemechanical strengthVSAvoidreactor size

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The patent merges the positioning function and insulation function into the inner core portions themselves by forming projections directly on them. This eliminates the need for separate inner interposed members, thereby reducing clearance size while maintaining mechanical strength and insulation performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the positioning function from the separate inner interposed members and transfers it to the inner core portions by forming projections on them. This allows the inner core portions to directly position the wound portions without requiring additional components, reducing overall reactor size.

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If gaps are formed in inner core portions to adjust inductance, then inductance control is achieved, but magnetic flux leakage increases causing eddy current loss

Engineering Contradiction:

Improveinductance adjustmentVSAvoideddy current loss

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent introduces resin material as an intermediary substance within the gaps formed in the inner core portions. This resin mediator allows inductance adjustment while preventing magnetic flux leakage, thereby reducing eddy current loss in the wound portions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of moving object

If clearances between wound portions and inner core portions are reduced, then reactor size is minimized, but positioning precision and mechanical stability become difficult to ensure

Engineering Contradiction:

Improvereactor sizeVSAvoidpositioning precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent forms projections on the inner core portions in advance during the molding process. These pre-formed projections automatically position the wound portions when assembled, ensuring precise positioning and mechanical stability even with reduced clearances, thereby achieving miniaturization without sacrificing manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

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

This design enables a more compact reactor with reduced clearances and improved mechanical strength, minimizing magnetic flux leakage and eddy current loss, while maintaining effective insulation and heat dissipation.

Implementation Method 1

a magnetic core including core pieces having inner core portions arranged inside of the wound portions. The core pieces are molded bodies of a composite material including a magnetic powder and a resin

Methodology Applied

Scientific EffectMagnetic flux guidance: Magnetic Field

Implementation Method 2

projections that are integrally molded with and protrude from outer peripheral surfaces of the inner core portions, and that position the wound portions in radial directions by coming into contact with inner peripheral surfaces of the wound portions

Methodology Applied

Scientific EffectMechanical positioning through contact: Mechanical Force

Implementation Method 3

inner resin portions that fill spaces between the inner peripheral surfaces of the wound portions and the outer peripheral surfaces of the inner core portions excluding the projections

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS11462354B2Reactor

Publication Date: 2022.10.04 AUTONETWORKS TECH LTD

AI summary

Provided is a reactor including: a coil having wound portions; and a magnetic core including core pieces having inner core portions arranged inside of the wound portions. The core pieces are molded bodies of a composite material including a magnetic powder and a resin, and the reactor includes: projections that are integrally molded with and protrude from outer peripheral surfaces of the inner core portions, and that position the wound portions in radial directions by coming into contact with inner peripheral surfaces of the wound portions; and inner resin portions that fill spaces between the inner peripheral surfaces of the wound portions and the outer peripheral surfaces of the inner core portions excluding the projections.