Reactor Core Positioning via Interposed Member
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Solution Overview
Problem
The manufacturing process of reactors housed in casings faces challenges in achieving high accuracy and productivity due to the complexity of positioning and integrating core pieces and gap members, often requiring adhesive tapes or similar methods.
Innovation Solution
A reactor design that incorporates inner and end surface interposed members with positioning portions to accurately position the magnetic core and coil components without the need for adhesives, allowing for flexible modification of the core shape and improved assembly workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive agents or adhesive tapes are used to integrate core pieces and gap members, then the magnetic core can be assembled, but the manufacturing process becomes complex and productivity decreases
Solution Approach 1:
An interposed member is introduced as a mediator between the coil and the magnetic core. This interposed member includes positioning portions that engage with both the coil and the magnetic core, facilitating accurate positioning and integration without requiring adhesive agents or tapes. The interposed member acts as a mechanical intermediary that simplifies the assembly process while maintaining component integration.
2Manufacturing precision
If adhesive agents or adhesive tapes are used to integrate core pieces, then the magnetic core can be assembled, but productivity is reduced due to complex positioning requirements
Solution Approach 1:
The interposed member serves as a positioning intermediary that provides predetermined positioning portions engaging with both the coil and the magnetic core. This eliminates the need for complex positioning operations and adhesive application processes, thereby improving productivity while maintaining manufacturing precision through the mechanical positioning structure.
3Productivity
If adhesive tapes are used to integrate core pieces and gap members, then assembly can proceed, but the process requires high accuracy positioning that complicates manufacturing
Solution Approach 1:
The interposed member provides predetermined positioning portions that automatically ensure accurate positioning when the magnetic core is assembled. This mechanical positioning system eliminates the need for high-accuracy manual positioning operations, thereby improving productivity without sacrificing manufacturing precision.
4Ease of manufacture
If adhesive agents are used to integrate components, then the magnetic core can be formed, but the manufacturing process becomes more time-consuming and less efficient
Solution Approach 1:
The interposed member enables direct mechanical integration of the magnetic core components through engagement of positioning portions, eliminating the time-consuming adhesive application and curing processes. This significantly reduces manufacturing time while maintaining ease of manufacture through the simplified mechanical assembly process.
Data Source
AI summary
A reactor including: a coil that includes a winding portion; a magnetic core that includes an inner core portion that is located inside the winding portion and an outer core portion that is located outside the winding portion; an inner interposed member that is interposed between an inner surface of the winding portion and the inner core portion; and an end surface interposed member that is interposed between an end surface of the winding portion and the outer core portion. The inner interposed member is provided with first positioning portions that engage with the end surface interposed member and are located so as to respectively face a first pair of surfaces of the outer core portion to position the outer core portion, the first pair of surfaces being composed of a pair of surfaces that face each other.