Reactor Core Resin Molding for Strength and Heat Dissipation
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Solution Overview
Problem
Existing reactors face challenges in forming a resin mold portion that covers the outer periphery of a magnetic core while exposing the coil, due to protruding outer core pieces that block the introduction of molding material, leading to difficulties in achieving high connection strength and heat dissipation, especially in smaller reactor designs.
Innovation Solution
A reactor design with a magnetic core featuring inner and outer core pieces of varying cross-sectional areas and relative permeabilities, where the resin mold covers the connecting area between the core pieces, forming thick portions to enhance connection strength and expose the coil for improved heat dissipation, with introduction spaces facilitating easier molding material introduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the resin mold portion is made thicker to cover the connecting area between core pieces, then the connection strength between inner core pieces and outer core pieces is improved, but the overall size of the reactor increases
Solution Approach 1:
The resin mold portion is designed with varying thickness: a thick portion (0.5-2.0mm) specifically at the connecting area between core pieces to ensure strong bonding, and a thin portion (0.1-0.5mm) at other areas to minimize overall size. This localized thickness distribution provides high connection strength where needed while maintaining compact reactor dimensions.
2Reliability
If the outer core pieces are made to protrude from the wound portion, then the magnetic circuit is improved, but the introduction of molding material is blocked
Solution Approach 1:
The magnetic core is divided into inner core pieces (with smaller cross-sectional area) and outer core pieces (with larger cross-sectional area). The inner core pieces are positioned within the wound portion while outer core pieces extend outward, creating a segmented structure that maintains magnetic circuit integrity while allowing molding material to be introduced from the outer regions.
Solution Approach 2:
The inner core pieces are pre-positioned within the wound portion before the resin mold is formed. This preliminary placement creates a structured framework that guides the introduction of molding material from the outer core piece regions, ensuring proper positioning while facilitating the molding process.
3Strength
If the resin mold portion covers the outer periphery of the magnetic core, then the structural support is improved, but the heat dissipation is reduced
Solution Approach 1:
The resin mold portion is strategically positioned to cover only the connecting area between core pieces and provide structural support where needed, while deliberately exposing the outer periphery of the magnetic core. This localized coverage maintains structural integrity at critical joints while allowing maximum heat dissipation from the exposed core surfaces.
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
The design achieves high connection strength, reduced leakage flux, and excellent heat dissipation while maintaining a compact reactor size, allowing for efficient resin mold formation and low-loss operation.
Implementation Method 1
a magnetic core that is disposed inside and outside the wound portion and forms a closed magnetic circuit
Implementation Method 2
a resin mold portion that includes an inner resin portion disposed between the wound portion and the magnetic core
Data Source
AI summary
A reactor including: a coil having a wound portion; a magnetic core that is disposed inside and outside the wound portion and forms a closed magnetic circuit; and a resin mold that includes an inner resin disposed between the wound portion and the magnetic core, and does not cover an outer-peripheral face of the wound portion.