Reactor Magnetic Shield Layer Flux Leakage
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Solution Overview
Problem
Existing reactors face challenges in minimizing magnetic flux leakage while maintaining a small size, particularly when using magnetic mixtures with low permeability materials, which can lead to increased reactor size and complexity.
Innovation Solution
Incorporating a magnetic shield layer made of non-magnetic powder and resin on the outermost surface of the magnetic core, formed integrally with the core during production, to reduce magnetic flux leakage without the need for additional cover members or adhesives, thus simplifying the manufacturing process and reducing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the outer core is made of magnetic mixture with low magnetic permeability to reduce size, then the reactor size is reduced, but magnetic flux leakage to the outside increases
Solution Approach 1:
The outer core is divided into two distinct regions: an inner region made of magnetic mixture for size reduction, and an outer magnetic shield layer made of high-permeability magnetic material for flux containment. This segmentation allows each region to perform its specific function optimally without compromising the other.
Solution Approach 2:
The outer core combines two different materials with complementary properties: magnetic mixture (for compactness) and high-permeability magnetic material (for flux shielding). This composite structure resolves the contradiction by integrating the advantages of both materials while eliminating their individual disadvantages.
2Object-generated harmful factors
If a cover member is added to reduce magnetic flux leakage, then magnetic flux leakage is reduced, but the number of parts and assembly steps increases
Solution Approach 1:
The magnetic shield layer is integrated directly into the outer core structure, merging the flux shielding function with the core itself. This eliminates the need for separate cover members and reduces the number of parts while maintaining effective flux containment.
Solution Approach 2:
The outer core serves multiple functions: it provides structural support, enables compact size through magnetic mixture, and contains magnetic flux through the magnetic shield layer. This multi-functionality eliminates the need for additional dedicated components.
3Object-generated harmful factors
If the outer core thickness is increased to reduce magnetic flux leakage, then magnetic flux leakage is reduced, but the reactor height and overall size increase
Solution Approach 1:
High magnetic permeability material is concentrated specifically in the outer magnetic shield layer where it is most needed for flux containment, while the inner region uses magnetic mixture for size reduction. This localized application of material properties achieves flux control without uniformly increasing overall dimensions.
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 effectively minimizes magnetic flux leakage and maintains a compact size by integrating the magnetic shield layer with the core, enhancing productivity and reducing the number of components and assembly steps.
Implementation Method 1
a magnetic shield layer made of non-magnetic powder, having smaller specific gravity than the magnetic powder and having electrical conductivity, and resin
Data Source
AI summary
A reactor 1α includes one coil 2, a magnetic core 3 to which the coil 2 is arranged, and a case 4 containing an assembly 10 of the coil 2 and the magnetic core 3. The magnetic core 3 includes an inner core portion 31 inserted into the coil 2, and a coupling core portion 32 disposed around the coil 2. The coupling core portion 32 is made of a mixture of magnetic powder and resin. The coil 2 is covered with the coupling core portion 32 and is enclosed within the case 4 in a sealed state. The reactor 1α includes, in an outermost surface region exposed at an opening of the case 4, a magnetic shield layer 5 made of non-magnetic powder, having smaller specific gravity than the magnetic powder and having electrical conductivity, and the resin. A small reactor capable of reducing magnetic flux leaked to the outside is thereby provided. A method of producing a small reactor capable of reducing magnetic flux leaked to the outside is also provided which produces the reactor 1α by filling the case 4 with a mixture of magnetic powder, non-magnetic powder, and resin, producing a state where the non-magnetic powder has floated to the opening side of the case 4 and the magnetic powder has precipitated on the bottom side of the case 4, and hardening the resin.