Reactor Core Wedge Structure for Stable Magnetic Contact
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Solution Overview
Problem
Existing reactors face challenges in maintaining a long-term contact state between core pieces, which can lead to flux leakage and manufacturing inefficiencies due to wear or deterioration of resin pressing protrusions.
Innovation Solution
A reactor design featuring a magnetic core with inclined surfaces on both the case and core pieces, allowing for surface contact that maintains core piece contact without adhesives, ensuring manufacturability and preventing flux leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin pressing protrusions are used to fasten the magnetic core, then the magnetic core can be fastened in the axial direction without adhesive, but the pressing protrusions may become worn or deteriorate with time, causing the contact state of core pieces to change
Solution Approach 1:
The invention changes the geometric parameters of the core pieces by providing inclined surfaces on the outer edge faces. This allows the core pieces to be pressed against the case wall with axial pressing force, utilizing friction and normal force components to maintain contact without relying on resin protrusions that wear over time.
Solution Approach 2:
The inclined surfaces on the core pieces create a wedge-like geometric configuration that converts axial pressing force into radial contact force between core pieces. This geometric transformation maintains reliable contact without requiring adhesive or resilient pressing structures.
2Reliability
If adhesive is used to join core pieces together, then the contact state can be maintained, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The invention extracts and eliminates the adhesive joining process from the manufacturing workflow. By using inclined surfaces and axial pressing force to maintain core piece contact, the design removes the need for adhesive application, curing time, and associated quality control steps, thereby improving manufacturing efficiency.
Solution Approach 2:
The invention replaces the chemical bonding mechanism (adhesive) with a mechanical solution (inclined surfaces and pressing force). This substitution eliminates the need for chemical processes while maintaining reliable contact between core pieces, significantly improving manufacturing productivity.
3Reliability
If core pieces are assembled with tight tolerances to maintain contact, then flux leakage is prevented, but the manufacturing precision requirements increase and production becomes more difficult
Solution Approach 1:
The invention introduces a dynamic pressing mechanism where axial pressing force is applied to the core pieces, causing them to press against each other through the inclined surfaces. This dynamic contact pressure compensates for tolerance variations and ensures consistent contact without requiring extremely tight manufacturing tolerances.
Solution Approach 2:
The inclined surfaces are pre-configured on the core pieces during manufacturing, creating a built-in mechanism that automatically maintains contact when axial force is applied. This preliminary geometric configuration eliminates the need for post-assembly adjustments or precision alignment procedures.
Data Source
AI summary
A reactor includes a coil having a winding portion; a magnetic core; and a case. The magnetic core includes a plurality of core pieces forming a closed magnetic circuit. The core pieces include two outer core pieces having a portion disposed outside the winding portion. The case includes a first and a second opposing faces are respectively opposed to outer edge faces of the outer core pieces, and a case inclined surface provided on at least one of the first and the second opposing faces. The case inclined surface is inclined such that a distance between the first opposing face and the second opposing face decreases from an opening side of the case toward an inner bottom face of the case, and a core inclined surface on the outer edge face side of the outer core piece is in surface contact with the case inclined surface.