Reactor Interposed Insulating Member for Assembly-Free Bonding
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Solution Overview
Problem
Existing reactors for electric-powered vehicles require holding the assembly during bonding to prevent the coil from contacting the mounting plate, which is cumbersome and risks assembly misalignment due to the weight and adhesion of resin-based heat dissipating layers.
Innovation Solution
A reactor design featuring a metal mounting plate with a bonding layer and an interposed insulating member composed of divided pieces with engaging portions and leg pieces that separate the coil from the mounting plate, allowing assembly without holding, ensuring secure fixation and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a resin-based heat dissipating layer is used as a bonding layer to fix the assembly to the mounting plate, then heat dissipation and adhesiveness are improved, but the assembly sinks into the uncured bonding layer and requires holding during manufacturing
Solution Approach 1:
The patent introduces a support member as an intermediary component between the assembly and the bonding layer. This support member prevents the assembly from sinking into the uncured resin while still allowing heat to be transmitted to the mounting plate, thus resolving the contradiction between heat dissipation and ease of manufacture
Solution Approach 2:
The support member is placed in advance on the mounting plate before the bonding layer is applied. This preliminary action ensures that when the assembly is later placed on the bonding layer, it is immediately supported and prevented from sinking, eliminating the need for holding during the curing process
2Ease of manufacture
If the assembly is placed on uncured bonding layer without support, then the bonding process is simplified, but the coil contacts the mounting plate causing misalignment and potential damage
Solution Approach 1:
The support member acts as a mediator that maintains the proper spacing between the assembly and the mounting plate. It prevents the coil from contacting the mounting plate while still allowing the bonding layer to cure properly, thus maintaining manufacturing precision without complicating the bonding process
Solution Approach 2:
The support member provides preliminary anti-action by preventing the assembly from sinking into the uncured bonding layer before the bond is fully established. This preliminary prevention of misalignment ensures that the assembly remains in the correct position throughout the curing process
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
Enables manufacturing without holding the assembly during bonding, maintaining separation between the coil and mounting plate, and improving heat dissipation and insulation, while preventing assembly misalignment and enhancing productivity.
Implementation Method 1
a bonding layer that fixes the assembly to the mounting plate
Implementation Method 2
an installation surface portion (mounting plate), which is a bottom surface of the casing, is made of metal in order to let heat generated in the assembly efficiently escape to the outside
Data Source
AI summary
Provided is a reactor that can be manufactured without holding an assembly when the assembly is fixed to a mounting plate via a bonding layer. The reactor includes a coil, a magnetic core, an interposed insulating member, a metal mounting plate, and a bonding layer. The interposed insulating member is provided with an inwardly interposed portion, a first interposed end face portion, and a second interposed end face portion. The interposed insulating member is obtained by combining a plurality of divided pieces that includes a divided piece having the first interposed end face portion, and a divided piece having the second interposed end face portion. The divided pieces are respectively provided with engaging portions that engage with each other, and the first interposed end face portion and the second interposed end face portion are each provided with a leg piece that separates the coil from the mounting plate.