Reactor Magnetic Core Strength via Unidirectional Resin Flow
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Solution Overview
Problem
Reactor designs with magnetic cores formed by inner and outer core pieces suffer from reduced strength due to welds and thermal stress, which can lead to cracking, especially when resin is introduced unsolidified and flows in different directions, merging between core pieces.
Innovation Solution
A reactor design that incorporates a frame and plate-shaped interposed member with specific through holes to control resin flow unidirectionally, preventing weld formation between core pieces and enhancing resin integration for increased magnetic core rigidity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin is introduced through through holes of frame-shaped bobbins and coil interior space to form resin mold portion, then the magnetic core can be integrated and rigidity can be increased, but flows of unsolidified resin with different flow directions may merge between inner core pieces and outer core pieces forming welds that reduce strength
Solution Approach 1:
The invention divides the resin introduction system into multiple independent through holes (first through hole in frame portion, second through hole in plate-shaped portion) that introduce resin from different directions. These segmented flow paths allow controlled unidirectional flow into the coil interior space without merging flows between core pieces, preventing weld formation while achieving complete resin coverage for magnetic core integration.
Solution Approach 2:
The coil interior space acts as an intermediary chamber that receives resin from multiple through holes and distributes it unidirectionally to the magnetic core assembly. This intermediary space prevents direct merging of resin flows between inner core pieces and outer core pieces, allowing the resin to solidify without forming vulnerable welds while still achieving complete integration.
2Manufacturing precision
If multiple through holes are used for resin introduction, then resin can reach all core pieces, but complex flow patterns may cause weld formation at flow merge points
Solution Approach 1:
The invention positions through holes at specific locations (frame portion and plate-shaped portion) and designs their orientations to create locally optimized unidirectional flow patterns. The resin flow direction is controlled to move uniformly toward the coil interior space without creating convergence zones where flows would merge and form welds, ensuring both complete coverage and high strength.
3Stability of the object's composition
If resin mold portion covers entire magnetic core assembly, then integration and rigidity are improved, but thermal stress during resin solidification may cause cracking
Solution Approach 1:
The invention pre-establishes a unidirectional resin flow path through specifically positioned through holes before resin introduction. This preliminary flow path design ensures uniform resin distribution and prevents localized overheating or rapid solidification that would create thermal stress concentrations, allowing the resin mold portion to cover the entire magnetic core assembly without causing cracking during solidification.
Data Source
AI summary
Provided is a reactor with enhanced strength. The reactor includes a coil, a magnetic core, an interposed member interposed between the coil and the magnetic core, and a resin mold portion. The interposed member includes a frame portion that has a first through hole, and a plate-shaped portion. The resin mold portion includes an interposed resin portion that is formed by a constituent resin of the resin mold portion being filled inside the first through hole, an inner side resin portion is formed by the constituent resin being filled inside a portion of a coil interior space, and an outer side resin portion. The plate-shaped portion includes an interposed wall portion, and a second through hole that is provided locally in a portion other than the interposed wall portion, and inside of which the constituent resin is filled.