Reactor Terminal Platform Integrated Design
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Solution Overview
Problem
Conventional reactors face challenges in reducing height while maintaining terminal platform strength and ensuring component arrangement space due to the difficulty in molding a terminal platform above the outer core portions, which can lead to terminal platform bending or breaking under fastening forces.
Innovation Solution
The reactor design integrates a terminal platform and fixing portion in one piece on the outer resin portion, with the terminal platform being thinner than the fixing portion, ensuring strength and reducing height, and embeds nuts within the terminal platform for secure fastening and reduced wear debris dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the terminal platform is molded in one piece with the outer resin portion above the outer core portions, then the terminal platform strength is improved, but the reactor height increases and installation space is reduced
Solution Approach 1:
The patent changes the spatial arrangement by positioning the terminal platform laterally adjacent to the outer core portions rather than above them. This dimensional repositioning allows the terminal platform to be formed integrally with the outer resin portion while avoiding vertical stacking, thus maintaining structural strength without increasing reactor height.
Solution Approach 2:
The patent segments the reactor structure into distinct functional zones: the outer resin portion covers the outer core portions, while the terminal platform is positioned in a separate lateral region. This segmentation allows each component to be optimized independently - the outer resin portion provides structural support and coverage, while the terminal platform provides electrical connection functionality without interfering with the vertical height constraint.
2Length of stationary object
If the terminal platform is made thinner to reduce height, then the reactor height is reduced, but the terminal platform strength decreases and may bend or break under fastening forces
Solution Approach 1:
The patent merges the terminal platform with the outer resin portion into a single integrally molded component. This combination allows the outer resin portion to provide structural support and rigidity to the terminal platform, enabling the terminal platform to be thin (reducing height) while maintaining sufficient strength to withstand fastening forces through the combined structural integrity of the integrated component.
3Ease of manufacture
If the terminal platform and fixing portion are made as separate components, then manufacturing flexibility is improved, but assembly complexity increases and manufacturing costs rise
Solution Approach 1:
The patent combines the terminal platform and fixing portion into a single integrally molded component formed from the outer resin portion. This merger eliminates the need for separate assembly steps, reduces the number of parts, simplifies manufacturing processes, and lowers costs while maintaining all necessary functions - electrical connection through the terminal platform and mechanical fixation through the fixing portion.
Data Source
AI summary
Provided is a reactor including a coil that has wound portions formed by winding a winding wire, and a magnetic core that includes inner core portions arranged inside of the wound portions and outer core portions arranged outside of the wound portions. The reactor includes an outer resin portion covering at least outer surfaces of the outer core portions. A terminal platform is formed in one piece protruding on the outer surface of an outer resin portion among the outer resin portions and has fastening portions configured to fasten terminal fittings connected to end portions of the winding wire to terminals of an external wiring. A fixing portion is formed in one piece on the terminal platform and fixes the reactor to an installation target. The terminal platform and the fixing portion are integrated and the thickness of the terminal platform is less than that of the fixing portion.