Reactor Resin Guide Structure for Stable Lead Wire Fixation
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Solution Overview
Problem
The existing reactor designs face inefficiencies in fixing lead wires due to vibration, which leads to interference with reactor components and requires additional parts and time for fixing, reducing production efficiency.
Innovation Solution
A reactor design that incorporates a resin member with a guide and intermediate guide portion to securely hold lead wires in place without the need for binding bands, allowing for easy fixation and reduced part count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead wires are fixed with binding bands to predetermined locations, then the lead wires are secured and do not move due to vibration, but the number of parts increases and fixing work takes a long time, resulting in poor production efficiency
Solution Approach 1:
The binding band is merged with the resin member to form an integrated structure. The resin member itself forms the binding band that wraps around and secures the lead wire, eliminating the need for separate binding band components and reducing assembly steps while maintaining secure lead wire fixation against vibration.
Solution Approach 2:
The resin member serves multiple functions: it provides electrical insulation, structural support, and lead wire fixation. By making the resin member multi-functional, the patent eliminates the need for separate binding bands and reduces the total number of parts while improving production efficiency.
2Reliability
If binding bands are used to fix lead wires, then the lead wires are secured, but the number of parts increases
Solution Approach 1:
The binding band function is merged into the resin member structure. The resin member forms an integrated assembly that includes both the insulating housing and the lead wire securing mechanism, eliminating separate binding band parts and reducing overall device complexity.
Solution Approach 2:
The resin member is designed to perform multiple functions simultaneously: electrical insulation, mechanical support, and lead wire fixation. This multi-functionality reduces the total number of parts needed while maintaining reliable lead wire securing.
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 design effectively secures lead wires without increasing the number of parts, improving production efficiency and reducing production time by simplifying the fixation process.
Implementation Method 1
current flows through the coil, magnetic flux is generated that penetrates the coil, and a closed magnetic circuit is formed in the core
Data Source
AI summary
Reactor 10 includes the core 4, the coil 2 attached to the core 4, the resin member 5 covering a periphery of the core 4, and the fastening portion 53 fastening the external terminal 61 of the external device electrically connected to the coil 2. The external terminal 61 is connected to the lead wire 62 connecting the external terminal 61 and the external device. The lead wire 62 is wired linearly above the core 4 along the core 4 to which the coil 2 is not attached. The resin member 5 includes the guide portion 54 provided at an opposite of the fastening portion 53 so as to interpose the core 4 above which the lead wire 62 is wired and holding the lead wire 62 and the intermediate guide portion 55 provided between the fastening portion 53 and the guide portion 54 and holding the lead wire 62.