Reactor Coil-Core Support Structure for Vibration Noise Suppression
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Solution Overview
Problem
Reactor designs face challenges in minimizing noise associated with vibration while preventing assembly detachment from the case, especially in compact installations where horizontal placement of winding portions is not feasible, leading to increased noise transmission and potential detachment issues.
Innovation Solution
The reactor incorporates a vertically stacked or upright arrangement of winding portions within a rectangular frame case, utilizing a cantilever-supported supporting portion fixed to the short side of the case, which enhances stability and noise absorption, reducing the installation area and component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If winding portions are arranged horizontally on the same plane, then the installation area is reduced, but the assembly becomes unstable and prone to detachment
Solution Approach 1:
The patent transitions from horizontal arrangement of winding portions to a vertical stacked arrangement, changing the spatial dimension from 2D plane to 3D stacking. This dimensional change allows the assembly to maintain stability through vertical support structures while keeping the horizontal installation footprint compact.
Solution Approach 2:
The patent employs composite construction by integrating the supporting portion with the case structure, creating a unified assembly that combines mechanical support and structural housing. This composite approach enhances overall assembly stability while maintaining compact dimensions.
2Stability of the object's composition
If the assembly is firmly fixed to prevent detachment, then stability is improved, but noise from vibration increases
Solution Approach 1:
The patent introduces the supporting portion as an intermediary element between the assembly and the case. This intermediary structure provides mechanical support for stability while its design allows it to absorb and dampen vibrations, preventing noise transmission to the case structure.
Solution Approach 2:
The patent modifies the physical parameters of the supporting portion, specifically its dimensions and material properties, to optimize the balance between providing sufficient mechanical support for stability and having adequate vibration damping characteristics to reduce noise generation.
3Area of stationary object
If a compact design is used to reduce installation area, then space efficiency is improved, but the assembly becomes prone to detachment
Solution Approach 1:
The patent utilizes vertical stacking of winding portions and vertical extension of the supporting portion to achieve compact horizontal footprint while maintaining reliable mechanical connection. The supporting portion extends vertically to engage with the case, providing secure attachment in a space-efficient manner.
Solution Approach 2:
The integrated composite structure of the supporting portion and case creates a unified assembly that enhances reliability. The composite design ensures robust mechanical connection while maintaining compact overall dimensions suitable for space-constrained installations.
Data Source
AI summary
A reactor includes an assembly of a coil and a magnetic core, a case for accommodating the assembly inside, a sealing resin portion for at least partially sealing the assembly by being filled into the case, and a supporting portion to be fixed to the case in a cantilever manner. The case includes a bottom plate portion, and a side wall portion. The side wall portion includes a pair of short side portions and a pair of long side portions having different lengths along a circumferential direction of the case. The supporting portion includes a fixed end to be fixed to an end surface of the short side portion of the side wall portion, an overlapping region configured to overlap the outer core portion from above, and a free end not to be fixed to the case.