Reactor Core Vibration Damping via Intermediary Resin Layer
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Solution Overview
Problem
Reactors in electric power converting apparatuses, such as vehicle-mounted DC-DC converters, face damage from vibrations and increased noise due to direct contact between the support portion and the magnetic core, which transmits stress and vibrations.
Innovation Solution
A reactor design where the sealing resin portion is interposed between the upper face of the outer core portion and the lower face of the support portion, preventing direct contact and thus reducing stress and vibration transmission, while firmly fixing the assembly to the casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the support portion is in direct contact with the exposed portion of the core to firmly fix the assembly to the casing, then the assembly can be firmly fixed to the casing, but stress may be applied to the core during vibrations and the core may be damaged
Solution Approach 1:
The patent introduces a resin layer as an intermediary substance between the support portion and the magnetic core. This resin layer serves as a mediator that maintains the fixation function while eliminating direct contact between the support portion and core, thereby preventing stress concentration and damage to the core during vibrations.
2Stability of the object's composition
If the support portion is fixed to the casing to provide structural support, then the assembly can be firmly fixed, but the support portion functions as a transmission path of vibrations from the core to the casing and noise increases
Solution Approach 1:
The resin layer acts as a vibration isolation intermediary between the magnetic core and the support portion. It absorbs and dampens vibrations, preventing them from being transmitted through the support portion to the casing, thereby reducing noise while maintaining assembly fixation.
Solution Approach 2:
The resin layer is applied beforehand between the support portion and the magnetic core to provide cushioning against vibrations. This pre-established cushioning layer prevents direct transmission of vibration energy, reducing noise generation before vibrations can propagate to the casing.
3Force
If the support portion presses the exposed portion of the core from above to ensure firm fixation, then the assembly can be firmly fixed to the casing, but direct contact causes stress application to the core during vibrations
Solution Approach 1:
The resin layer serves as a force-distributing intermediary between the support portion and the magnetic core. It allows the support portion to exert fixation force while distributing the stress over a larger area and preventing concentrated stress points that could damage the core during vibrations.
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 configuration effectively suppresses core damage and noise during reactor operation by reducing stress and vibration transmission, while ensuring secure assembly fixation.
Implementation Method 1
the sealing resin portion is interposed between the upper face of the outer core portion and a lower face of the support portion... suppress damage to a core thereof accompanying vibrations... reduce noise
Data Source
AI summary
Provided is a reactor configured to suppress damage to a core thereof accompanying vibrations during an operation of the reactor and to reduce noise, while fixing an assembly of a coil and the core to a casing. A reactor includes: a coil, a magnetic core and a coil, a casing and a sealing resin portion. The reactor includes a support portion that is attached to the casing and arranged so as to overlap an upper face of an outer core portion of the magnetic core exposed from the coil, and, together with the sealing resin portion, prevents detachment of the assembly from the casing, the sealing resin portion is interposed between an upper face of the outer core portion and a lower face of the support portion, and the outer core portion and the support portion are not in direct contact with each other.