Exposed-Winding Reactor Structure for Heat Dissipation and Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing reactors face challenges in achieving both excellent heat dissipation and manufacturability, as they often require complex assembly processes and may not efficiently dissipate heat due to resin coverage of winding portions.
Innovation Solution
A reactor design featuring a coil with exposed winding portions, a magnetic core housed within a resin cover, and an adhesive filling the gap between the core and cover, allowing direct contact with cooling media and simplifying manufacturing by eliminating the need for molding dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the coil is exposed from the resin molded portion to enable direct contact with cooling medium, then heat dissipationability is improved, but manufacturability deteriorates due to the need to place core pieces in molding die
Solution Approach 1:
The resin cover is divided into two separate parts: the main cover and the protruding portion. The protruding portion is detached from the main cover, allowing it to be inserted into the coil assembly after the coil is wound. This segmentation enables the coil to be exposed for heat dissipation while avoiding the complexity of placing core pieces in the molding die during manufacturing.
Solution Approach 2:
The protruding portion is designed to be inserted into the coil assembly in advance of final assembly, positioning it to form the adhesive portion that bonds the cover to the coil. This preliminary action simplifies the overall manufacturing process by pre-establishing the bonding structure before final assembly.
2Reliability
If the resin cover completely encloses the magnetic core for protection, then mechanical protection and insulation are improved, but heat dissipation deteriorates due to blocked cooling medium access
Solution Approach 1:
The resin cover is designed with localized exposure of the coil at specific positions where heat dissipation is critical. The protruding portion creates a localized adhesive bond that allows the coil to remain exposed in key areas while still providing overall protection. This local quality approach maintains protection where needed while enabling heat dissipation where most required.
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 enhances heat dissipation efficiency and manufacturability by enabling direct contact with cooling media and simplifying assembly, while providing mechanical protection and improved insulation for the magnetic core.
Implementation Method 1
an adhesive portion that is provided so as to fill a gap between an outer circumferential surface of a housing portion of the magnetic core and an inner circumferential surface of the resin cover, and bonds the housing portion and the resin cover
Data Source
AI summary
A reactor includes a coil having a winding portion; a magnetic core including an inner core portion and an outer core portion disposed outside the winding portion; a resin cover housing at least a portion of the magnetic core; and an adhesive portion filling a gap between an outer circumferential surface of a housing portion of the magnetic core and an inner circumferential surface of the resin cover bonding the housing portion with the resin cover. The resin cover includes: a flange portion having a surface that comes into contact with an end face of the winding portion and a through hole; an outer cover portion having housing portion housing the outer core portion and an abutting portion that contacts a portion of the flange portion; and a protruding portion that forms the gap between an outer circumferential surface of the outer core portion.