Reactor Terminal and Base Fastening Without Through-Hole
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Solution Overview
Problem
In reactors with multiple iron core coils, forming a through-hole to fasten the outer peripheral iron core shortens the gap length, leading to reduced magnetic flux and necessitates larger iron cores and outer peripheral iron cores to maintain inductance, which is undesirable for size constraints.
Innovation Solution
A reactor design featuring a core body with abutment members on a base and terminal that interpose the core body, allowing tight fastening of iron cores without the need for a central through-hole, thereby maintaining gap length without increasing core sizes, using a configuration with magnetically coupled gaps between iron cores and non-magnetic abutment members to prevent magnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a through-hole is formed in the center of the reactor to fasten the outer peripheral iron core, then the iron cores can be tightly fastened, but the gap length is shortened and inductance cannot be guaranteed
Solution Approach 1:
The fastening function is segmented from the center through-hole approach to distributed abutment members positioned at the ends of the core body. This segmentation allows the fastening force to be applied at the ends rather than through the center, avoiding interference with the magnetic flux path and gap length in the center region.
Solution Approach 2:
The fastening approach transitions from a central axial through-hole (one-dimensional approach) to end-positioned abutment members (two-dimensional distribution). By moving the fastening points to the ends of the core body in the axial direction, the magnetic flux path in the radial direction is preserved, maintaining both gap length and inductance.
2Reliability
If the gap length is increased radially outward to guarantee inductance, then inductance can be maintained, but the iron cores and outer peripheral iron core become larger
Solution Approach 1:
Instead of increasing gap length radially outward to maintain inductance, the invention inverts the approach by preserving the original gap length through proper fastening positioning. The abutment members are placed at the ends to fasten the core without interfering with the magnetic flux path, thereby maintaining inductance without increasing core size.
3Stability of the object's composition
If a through-hole is formed in the center of the core body, then fastening can be achieved, but magnetic flux is interrupted and inductance is reduced
Solution Approach 1:
The fastening function is extracted from the center region where it would interrupt magnetic flux, and relocated to the end regions where it does not interfere with the magnetic circuit. The abutment members are positioned at the ends of the core body, taking the fastening action out of the magnetic flux path while maintaining fastening capability.
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 allows for tight fastening of iron cores without enlarging the reactor components, ensuring consistent inductance and reducing magnetic field leakage, while maintaining design advantages and cost-effectiveness.
Implementation Method 1
a first abutment member attached to the base and is configured to abut one end of the at least three iron cores between the base and the core body, and a second abutment member attached to the terminal and is configured to abut the other end of the at least three iron cores between the core body and the terminal
Implementation Method 2
gaps, which can be magnetically coupled, are formed between one of the at least three iron cores and another iron core adjacent thereto
Data Source
AI summary
A core body of a reactor includes an outer peripheral iron core composed of a plurality of outer peripheral iron core portions, at least three iron cores coupled to the plurality of outer peripheral iron core portions, and coils wound onto the at least three iron cores. The reactor includes a terminal and base which are fastened to the core body so as to interpose the core body therebetween, a first abutment member attached to the base and is configured to abut one end of the at least three iron cores between the base and the core body, and a second abutment member attached to the terminal and is configured to abut the other end of the at least three iron cores between the core body and the terminal.