Reactor Core Positioning via Resin Molding Segmentation
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Solution Overview
Problem
Conventional vehicular reactor manufacturing methods face challenges in precisely positioning core members and spacers within a mold core due to complex die shapes and the need for additional bonding steps, leading to potential mispositioning and performance issues.
Innovation Solution
A reactor design featuring a first and second divisional core with exposed surfaces and cylindrical core attaching portions, allowing for precise positioning without pre-bonding, where the leg-portion-side core members and spacers are integrated into the resin molding, simplifying the manufacturing process and eliminating the need for complex die setups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple core members and spacers are set in a die for resin molding, then a mold core can be manufactured, but it is difficult to precisely position the core members and spacers leading to mispositioning
Solution Approach 1:
The invention divides the core structure into modular components: yoke-side core members that are molded together with the resin as a single unit, and leg-portion-side core members that are attached separately. This segmentation allows the yoke-side core members to be precisely positioned during resin molding without requiring complex die setups for multiple separate components, while the leg-portion-side core members can be attached using simpler subsequent processes.
Solution Approach 2:
The invention merges the yoke-side core members with the resin molding process, creating an integrated unit where the core members and resin are formed simultaneously. This merging eliminates the need for separate positioning and fixing steps for these components, achieving precise positioning without increasing die complexity. The leg-portion-side core members are then attached to this integrated unit in a separate, simpler step.
2Manufacturing precision
If each core member and spacer are connected by a bond in advance, then mispositioning can be suppressed, but the manufacturing procedure becomes complicated
Solution Approach 1:
The invention merges the positioning and fixation functions into the resin molding process itself. The resin acts as both the structural material and the positioning/fixing medium, eliminating the need for separate bonding operations. Core members are positioned in the die, resin is injected to fix them in place, and the resin cures to provide permanent positioning, all in a single integrated process.
Solution Approach 2:
The resin serves as an intermediary material that performs multiple functions: it structurally supports the core members, positions them precisely during molding, and provides permanent fixation upon curing. This intermediary approach replaces complex mechanical positioning and bonding systems with a simpler chemical-physical process.
3Manufacturing precision
If a complex die is used to suppress mispositioning of core members, then positioning can be improved, but the die becomes more complex and difficult to manufacture
Solution Approach 1:
The invention segments the core members into two groups with different positioning requirements: yoke-side core members that are positioned during resin molding using simple die features, and leg-portion-side core members that are attached afterward using simpler fixtures or adhesives. This segmentation allows each group to be positioned using appropriately simple methods rather than requiring a complex die for all components.
Solution Approach 2:
The invention performs preliminary positioning of the yoke-side core members during the resin molding process itself, where the resin fills gaps and locks components in place. This preliminary action achieves precise positioning without requiring complex pre-positioning fixtures or complex die structures, as the resin molding process naturally provides the positioning function.
Data Source
AI summary
First and second divisional cores each including right and left leg portions and a yoke interconnecting those together are formed by molding respective yoke-side core members in a resin. Cylindrical core mounting portions extending from the outer circumference of the surface of the yoke-side core member are formed integrally with the respective right and left leg portions of the first divisional core. I-shaped leg-portion-side core members and spacers are attached in the cylindrical core mounting portion formed in each of the right and left leg portions. The surface of the yoke-side core member molded in the resin and the surface of the leg-portion-side core member are disposed so as to have a spacer therebetween. The two divisional cores are joined together by butting respective leg portions of the two divisional cores with each other to form an annular mold core, and a coil is wound around the mold core.