Reactor Core Casing Structure to Prevent Gap Resin Deformation
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Solution Overview
Problem
In reactors, the resin material in the magnetic gap between partial cores is prone to deformation due to shrinkage, leading to positional instability and potential insulation failure between the core and coil.
Innovation Solution
A reactor design featuring a core molding member with a coupling portion that includes a through-hole and connection portions between partial cores, which suppresses deformation by providing structural rigidity and ensuring proper positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resin material is made thick to ensure insulation between core and coil, then insulation reliability is improved, but the resin material becomes prone to deformation due to shrinkage during curing
Solution Approach 1:
The invention introduces a through-hole penetrating the coupling portion of the core molding member, creating a porous structure within the resin material. This allows the resin to shrink into the through-hole during curing, preventing sink marks and deformation while maintaining adequate insulation thickness between the core and coil.
2Stability of the object's composition
If the resin material is made thin to prevent deformation, then resin material stability is improved, but insulation reliability and structural strength are reduced
Solution Approach 1:
The through-hole creates a porous structure that accommodates resin shrinkage during curing. This allows the use of thinner resin material without sink marks or deformation, while the hole itself provides additional shrinkage accommodation space to maintain structural integrity and insulation reliability.
3Reliability
If the resin material is made thick to ensure insulation, then insulation reliability is improved, but manufacturing precision deteriorates due to sink marks and concavity
Solution Approach 1:
The through-hole provides a dedicated space for resin shrinkage during curing, preventing sink marks and concavity formation. This maintains the dimensional accuracy and positioning precision of the core molding member while still providing adequate insulation thickness.
4Manufacturing precision
If the resin material is made thin to prevent deformation, then manufacturing precision is improved, but the strength of the coupling portion is reduced
Solution Approach 1:
The through-hole structure allows the coupling portion to be made thinner while maintaining positioning precision, as the hole accommodates shrinkage without causing deformation. The remaining resin material around the through-hole maintains sufficient strength for coupling the core components.
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 effectively prevents deformation of the resin material, maintaining insulation integrity and ensuring stable core positioning, thereby preventing mutual contact between the core and coil.
Implementation Method 1
when the resin material which covers the surroundings of a protruding portion of the core adjacent to the solid portion becomes thin due to shrinkage caused when the resin material becomes a low-temperature and cured state from a high-temperature state with fluidity
Data Source
AI summary
A reactor capable of suppressing a deformation of a resin material in a gap between partial cores is provided. This reactor includes: a core that includes T-shaped cores which are at least a pair of partial cores disposed via the gap therebetween; a coil attached to respective parts of the T-shaped cores; and a core casing that is a core molding member which is formed integrally by a resin material and which covers the T-shaped cores. The core casing includes the coupling portion that is provided between the T-shaped cores at a location corresponding to the gap, and the coupling portion is provided with a through-hole, and a pair of connection portions which face with each other across the through-hole and which connects a space between the T-shaped cores.