Reactor Magnetic Core Inward Recessed Portion Weight Reduction
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Solution Overview
Problem
In hybrid automobiles, reducing the weight of reactors while maintaining excellent magnetic characteristics is challenging, as minimizing the magnetic core size leads to deteriorated magnetic characteristics.
Innovation Solution
The reactor design incorporates inward recessed portions in the side cores, which reduce material usage and weight while minimizing magnetic flux leakage, maintaining magnetic characteristics through optimized recessed portion dimensions and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the size of the magnetic core is reduced to reduce weight, then weight decreases, but magnetic characteristics deteriorate
Solution Approach 1:
The side cores are provided with inward recessed portions at specific locations facing the winding portion, creating local variations in the magnetic path. This allows the magnetic core to have different properties in different regions - the recessed portions reduce weight and improve cooling while the overall magnetic path remains intact to maintain magnetic characteristics
Solution Approach 2:
The inward recessed portions extend in the thickness direction of the side cores, utilizing the Z-direction dimension. This allows weight reduction and cooling improvement without significantly affecting the magnetic path length in the X and Y directions, thereby maintaining magnetic characteristics while achieving weight reduction
2Weight of moving object
If the magnetic core size is reduced, then weight decreases, but conversion efficiency deteriorates
Solution Approach 1:
The inward recessed portions are strategically positioned in the side cores to create local cooling channels and reduce weight, while the overall magnetic core structure maintains its magnetic path integrity. This local modification approach improves heat dissipation and reduces weight without significantly affecting the magnetic characteristics and conversion efficiency
Solution Approach 2:
The inward recessed portions convert what would be wasted space into beneficial cooling channels that improve heat dissipation. The recessed areas allow better airflow or heat transfer medium circulation, turning the potential structural weakness into a thermal management advantage that indirectly supports conversion efficiency
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 reactor is lightweight with excellent magnetic characteristics, and the converter and power conversion device exhibit improved conversion efficiency due to reduced coil loss and weight reduction.
Implementation Method 1
a magnetic core, wherein the magnetic core includes: a middle core arranged inside the first winding portion, a first end core facing a first end face of the first winding portion, a second end core facing a second end face of the first winding portion
Data Source
AI summary
The magnetic core includes a middle core, a first end core, a second end core, a first side core, and a second side core. At least either the first side core or the second side core includes an inward recessed portion provided in an inward face that faces the first winding portion in a Y direction. In a plan view of the magnetic core from a Z direction, at least a portion of the inward recessed portion is overlapped with a range corresponding to the length of the first winding portion in an X direction. The X direction is a direction conforming to the axial direction of the middle core, the Y direction is a direction in which the middle core, the first side core, and the second side core are side-by-side, and the Z direction is a direction orthogonal to the X direction and the Y direction.