Reactor Resin Filling via Insertion Member Gap
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Solution Overview
Problem
Reactor designs that utilize a sealing resin portion for heat dissipation require large amounts of resin, leading to longer filling times and potential variations in heat dissipation performance, especially when narrow gaps are involved, and high viscosity resin further complicates the filling process.
Innovation Solution
A reactor design that includes an insertion member with a type A durometer hardness of 50 or higher, which separates from the case's bottom portion via a gap, creating a space for the resin to flow and fill, reducing the resin amount needed while ensuring effective heat dissipation by using a combination of first and second resin portions to fill different regions, including narrow gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the sealing resin portion completely surrounds the assembly to improve heat dissipation performance, then heat dissipation performance is improved, but the filler amount of sealing resin increases and filling time becomes longer
Solution Approach 1:
The sealing resin portion is divided into a first resin portion and a second resin portion. The first resin portion fills a first region between the bottom portion and the leading end portion of the insertion member, while the second resin portion fills a second region between the assembly and the case. This segmentation reduces the total filler amount while maintaining heat dissipation performance by strategically placing resin in critical thermal pathways.
2Temperature
If regions with narrow gaps are provided between the assembly and case to improve heat dissipation, then heat dissipation performance is improved, but the raw resin cannot flow through such narrow regions and filling time becomes longer
Solution Approach 1:
The insertion member acts as an intermediary structure that creates a controlled space between the assembly and the case. By positioning the leading end portion of the insertion member at a specific distance from the bottom portion, a first region is formed that allows raw resin to flow easily. This intermediary structure enables the resin to reach narrow gap regions without direct resistance, facilitating complete filling while maintaining effective thermal pathways.
3Reliability
If the raw resin has high viscosity to improve sealing performance, then sealing performance is improved, but it becomes even more difficult to flow through narrow regions and filling time becomes longer
Solution Approach 1:
The insertion member is positioned in advance within the case, creating predetermined first and second regions before resin filling. This preliminary arrangement ensures that high-viscosity resin can flow into the first region without resistance and then into the second region, guaranteeing complete filling of narrow gaps. The pre-established spatial configuration allows high-viscosity resin to achieve proper sealing without extended filling times.
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 reduces the filler amount of sealing resin, shortens the filling time, and maintains excellent heat dissipation performance even in narrow gaps, improving manufacturability and thermal conductance.
Implementation Method 1
the sealing resin portion transmits the heat generated by the assembly to the case
Implementation Method 2
an insertion member that is stored side-by-side with the assembly in the case; and a sealing resin portion that fills the case. The case includes a bottom portion and a side wall portion. The insertion member includes a leading end portion disposed so as to be separated from the bottom portion via a gap, and a space is formed between the assembly and the case and between the insertion member
Data Source
AI summary
A reactor includes an assembly, stored in a case, including a coil and a magnetic core; an insertion member, having a type A durometer hardness of 50 or higher, that is stored side-by-side with the assembly; and a sealing resin portion that fills the case. The case includes a bottom portion and a side wall portion. The insertion member includes a leading end portion separated from the bottom portion via a gap. A space formed between the assembly and the case and between the insertion member and the case includes a first region provided between the bottom portion and the leading end portion and a second region that is a region other than the first region. The sealing resin portion includes a first resin portion that fills the first region and a second resin portion that fills at least a portion of the second region.