Reactor with Open Bottom Metal Casing and Resin Cover
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Solution Overview
Problem
Conventional reactors with metal casings and resin mold components require complex assembly steps and suffer from reduced inductance due to magnetic flux shielding, increasing manufacturing complexity and reactor loss.
Innovation Solution
A reactor design featuring an annular core with upper and lower E-shaped cores, a coil attached to the core's leg, resin covers for the core surfaces, and a metal casing with an open bottom plate to allow magnetic flux passage, along with a filler resin to secure components and enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the entire reactor is housed in a metal casing with a box shape having an opened upper surface, then the reactor structure is simple and manufacturing is easy, but the inductance decreases due to shielding effect against magnetic fluxes leaking from the back surface of the core
Solution Approach 1:
The patent divides the casing into two distinct parts: a metal casing (casing 6) that provides structural support and heat dissipation, and a resin cover (cover 5) that covers the back surface of the core to prevent magnetic flux shielding. This segmentation allows each material to perform its optimal function without the drawbacks of using a single material for the entire enclosure.
Solution Approach 2:
The patent applies different material properties to different locations of the reactor housing. The metal casing is used where structural strength and heat dissipation are needed (side surfaces and bottom), while the resin cover is applied specifically at the back surface of the core where magnetic flux passage is critical. This local differentiation of material quality resolves the contradiction between manufacturing simplicity and inductance maintenance.
2Stability of the object's composition
If a resin mold component covers the circumference of an annular magnetic core and is integrated with the core, then the core and resin molding are integrated, but an additional fastening step is required during assembly to prevent movement within the casing
Solution Approach 1:
The patent combines the resin cover (cover 5) with both the core and the metal casing through integral fastening. The resin cover is positioned to cover the back surface of the core while extending to engage with the casing, creating a unified structure where all three components (core, cover, casing) are simultaneously secured. This merging eliminates the need for separate fastening operations.
Solution Approach 2:
The resin cover is designed in advance to perform multiple functions: covering the core during the molding process and subsequently serving as a fastening element between the core and casing. By preparing the cover with this dual functionality beforehand, the patent eliminates the need for additional fastening steps during assembly.
3Strength
If the side surface of the casing is placed to face the yoke portion of the core, then the casing provides structural support, but the inductance decreases due to shielding effect against magnetic fluxes
Solution Approach 1:
The patent segments the housing structure into a metal casing for structural support and a resin cover for magnetic flux management. The resin cover is specifically positioned between the metal casing and the core's back surface, creating a magnetic flux-friendly zone that prevents the metal casing from interfering with magnetic field lines while maintaining structural integrity.
Solution Approach 2:
The resin cover acts as an intermediary layer between the metal casing and the core. Since resin is non-magnetic, it mediates the interaction between the metal casing and magnetic flux, allowing the metal casing to provide structural support without causing shielding effects. This intermediary material resolves the contradiction by decoupling the structural and magnetic functions.
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
Simplifies assembly by eliminating the need for fastening the core and resin molding within the casing, maintains high inductance by minimizing shielding effects, and improves heat dissipation through strategic resin and metal material usage.
Implementation Method 1
a filler resin filled in a gap between a circumference of the annular core and the coil, and the side wall of the casing or a side wall of the lower cover
Implementation Method 2
a casing formed of metal, including a bottom plate having an opening, and a side wall provided integrally with the bottom plate, in which the lower core, the coil, and the upper core are housed in the casing
Data Source
AI summary
An annular core includes an upper core and a lower core. A coil is attached to the leg of the annular core in a way that the winding axis is aligned in the vertical direction. The surface of the upper core is covered by an upper cover formed of resin. The surface of the lower core is covered by the lower cover formed of resin. A casing formed of metal includes a bottom plate having an opening, and a side wall integrated with the bottom plate, and the lower core, the coil, and the upper core are housed in the casing. A part of the lower cover is exposed via the opening of the casing. A filler resin is filled in a gap between the circumference of the annular core and the coil, and the side wall of the casing or the lower cover.