Reactor Mold Layout for Preventing Core Leg Collapse
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Solution Overview
Problem
In the manufacturing of reactors, the thinning of core legs to reduce reactor size leads to resin flow paths that impose pressure on core leg parts from the outside, causing potential collapse and damage due to lack of inner support.
Innovation Solution
A method and mold configuration where the resin is poured from a gate located closer to the coil than the core legs, with an outer surface support for the core legs and a blocking part to redirect resin flow, ensuring pressure is applied from the inside out and maintaining core leg integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the core legs are thinned to reduce reactor size, then the reactor size is reduced, but the core leg parts may collapse inward and deform due to pressure from resin flowing through the outer peripheral flow channel
Solution Approach 1:
The support part is provided on the mold to support the outer surface of each core leg part before resin injection occurs. This preliminary support prevents the core leg parts from collapsing inward when resin pressure is applied during the molding process, thereby maintaining structural integrity while allowing thinning of the core legs for reduced reactor size
Solution Approach 2:
Instead of providing the gate on the outer side of the core leg parts (conventional approach), the gate is positioned on the inner side. This inversion changes the resin flow direction so that resin flows through the inner peripheral flow channel first, applying pressure from the inside outward, which naturally supports the core leg parts and prevents inward collapse
2Ease of manufacture
If gates are provided on the mold on the core leg parts, then resin molding can be performed, but the length of the resin flow path is longer in the inner peripheral flow channel than in the outer peripheral flow channel, causing uneven resin distribution
Solution Approach 1:
The gate is positioned on the inner side of the mold rather than on the outer side of the core leg parts. This inversion makes the outer peripheral flow channel longer than the inner peripheral flow channel, allowing resin to fill the inner channel first and ensuring more uniform resin distribution and shorter overall flow paths for better manufacturing precision
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
This configuration prevents core leg collapse and damage by ensuring appropriate resin flow paths and support, effectively maintaining the structural integrity of the reactor core during the manufacturing process.
Implementation Method 1
an inner peripheral flow channel through which the resin flows may be formed between an inner peripheral surface of each of the core leg parts and an outer peripheral surface of the coil
Data Source
AI summary
To prevent a core from being damaged. A method for manufacturing a reactor includes a step of assembling a core that is configured of a core center part and a pair of core leg parts extending outwardly from the core center part to a coil in such a way that the core center part is inserted into a hollow part of the coil and the coil is sandwiched between the core center part and the pair of the core leg parts; and a step of performing resin molding by disposing the coil and the core that are assembled inside a mold and pouring resin into the mold from a gate provided on the mold to the side which is closer to the coil than the core legs parts are while having an outer surface of each of the core leg parts supported by a support part provided on the mold.