Reactor Core Assembly with Protruding Divisional Pieces
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Solution Overview
Problem
Existing reactor designs face challenges in maintaining the interval between core pieces while simplifying the configuration and improving productivity, as conventional methods require additional manufacturing steps and resin distribution complexities.
Innovation Solution
The reactor incorporates inner divisional pieces with protruding portions to maintain the interval between core pieces, eliminating the need for gap plates and simplifying assembly, and uses a resin mold portion to efficiently distribute unsolidified resin and form resin gap portions during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional tubular bobbins are used to cover the entire outer circumferential surfaces of stacked objects, then mechanical protection is achieved, but the configuration becomes complex and productivity decreases due to additional assembly steps
Solution Approach 1:
The tubular bobbin is divided into two divisional pieces that can be assembled together. This segmentation allows the bobbins to be more easily manufactured and assembled around the stacked objects, reducing the complexity of the overall configuration while still providing the necessary mechanical protection.
2Manufacturing precision
If gap plates are used to maintain intervals between core pieces, then the interval is reliably maintained, but the manufacturing process becomes more complex with additional steps
Solution Approach 1:
The interval maintenance function previously performed by separate gap plates is merged into the tubular bobbins themselves. The bobbins are designed to directly maintain the intervals between core pieces while providing mechanical protection, eliminating the need for separate gap plate components and simplifying the manufacturing process.
3Strength
If resin is used to cover the combined body, then mechanical protection is provided, but resin distribution becomes complex and productivity decreases
Solution Approach 1:
The tubular bobbins are pre-assembled around the stacked objects before the resin covering process. This preliminary action creates a structured framework that guides resin distribution, preventing complex resin flow patterns and air traps, thereby improving manufacturing efficiency and productivity.
4Strength
If the outer circumferential surface of the winding portion is covered by resin, then mechanical protection is improved, but the winding portion cannot be accessed for inspection or maintenance
Solution Approach 1:
The resin covering is applied selectively to cover only the magnetic core and tubular bobbins, while leaving the winding portion's outer circumferential surface exposed. This local quality approach provides mechanical protection where needed (core and bobbins) while maintaining accessibility for inspection and maintenance of the winding portion.
Data Source
AI summary
A reactor that includes a coil that includes a winding portion; a magnetic core that includes a plurality of core pieces that are located inside and outside the winding portion, and one or more gap portions that are interposed between core pieces that are adjacent to each other; an interposed member that is interposed between the coil and the magnetic core; and a resin mold portion that covers at least a portion of an outer circumferential surface of the magnetic core without covering an outer circumferential surface of the winding portion so that the outer circumferential surface of the winding portion is exposed.