Resin-Locked Reactor Core Structure for Compact Magnetic Assembly
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Solution Overview
Problem
Existing reactors face challenges in firmly holding a magnetic core as a single body due to inadequate adhesion between the core pieces and the resin molded portion, leading to potential separation and increased size, which affects the reactor's compactness.
Innovation Solution
The reactor design incorporates a magnetic core with an inner core portion having a groove structure intersecting the axial direction, filled with resin, and a continuous resin portion that covers both the inner and outer core surfaces, forming a fitting structure to securely hold the core pieces as a single body without excessive resin thickness, allowing for a smaller reactor size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the resin molded portion is increased to improve adhesion between the core piece and the resin molded portion, then the adhesion strength is improved, but a large gap needs to be secured between the winding portion and the inner core pieces, resulting in an increase in the size of the reactor
Solution Approach 1:
The invention transitions from increasing resin thickness in one dimension to creating adhesion through groove structures in multiple dimensions. The groove portions extend in radial, axial, and circumferential directions, providing multi-dimensional mechanical interlocking between the resin and inner core pieces, thereby achieving strong adhesion without increasing overall reactor size.
Solution Approach 2:
The groove portions create a porous-like structure within the inner core pieces that allows the resin to penetrate and form mechanical interlocking. This increases the surface area for adhesion and creates anchoring points, enabling strong bonding without requiring excessive resin thickness.
2Stability of the object's composition
If the thickness of the resin molded portion is increased to firmly hold the magnetic core as a single body, then the holding strength is improved, but the space between the winding portion and the inner core pieces increases, resulting in a larger reactor
Solution Approach 1:
The groove portions extend in radial, axial, and circumferential directions, creating three-dimensional mechanical interlocking. This multi-dimensional structure provides comprehensive holding strength that stabilizes the magnetic core as a single body without requiring increased resin thickness or larger reactor dimensions.
Solution Approach 2:
The invention creates a composite structure where the resin and inner core pieces form an integrated single body through the groove portions. The resin penetrates the grooves and bonds with the inner core pieces, creating a composite material system with enhanced holding strength and structural stability.
3Device complexity
If insufficient adhesion is obtained between the core piece and the resin molded portion, then the reactor structure is simpler, but the core pieces separate and the reactor size increases
Solution Approach 1:
The inner core pieces are divided into multiple segments with groove portions created on their surfaces. These grooves allow the resin to penetrate and bond with each segment, ensuring that all core pieces are firmly held together as a single body without requiring complex overall structural design or excessive resin thickness.
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 effectively maintains the magnetic core as a single body, reducing the space between the winding portion and the inner core, and ensures reliable adhesion, resulting in a compact and stable reactor configuration.
Implementation Method 1
sufficient adhesion between the core piece and the resin molded portion cannot be obtained
Data Source
AI summary
Provided is a reactor that includes a coil having a winding portion, a magnetic core having an inner core portion and an outer core portion, and a resin molded portion covering a surface of the magnetic core. The inner core portion is a single body having a non-separated structure, and includes a groove portion provided along a direction intersecting with the axial direction in a surface in the vicinity of an end portion of the inner core portion located in the axial direction. The resin molded portion includes an outer resin portion and an inner resin portion that covers the surface of the end portion of the inner core portion located in the axial direction and with which an inner portion of the groove portion is filled. The inner resin portion is continuous with the outer resin portion.