Reactor With Through Hole in Outer Core for Resin Filling
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Solution Overview
Problem
Existing reactor designs often fail to fill the internal space of the winding portion with a sufficient amount of resin, leading to reduced resin strength and potential damage from vibrations during use.
Innovation Solution
A reactor design that includes a through hole in the outer core portion allowing resin to fill the gap between the winding and magnetic core components, ensuring a sufficient resin fill and improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the internal space of the winding portion is filled with resin from the conventional method, then the resin filling process is simple, but the resin cannot fill the internal space sufficiently leading to reduced resin strength
Solution Approach 1:
The outer core portion is divided to include a through hole that segments the resin filling path, allowing resin to access the internal space of the winding portion from multiple directions (both from the outer side through the through hole and from the inner side), ensuring complete and sufficient resin filling throughout the structure
Solution Approach 2:
The through hole in the outer core portion acts as an intermediary channel that facilitates resin flow into the internal space of the winding portion, enabling the resin to reach areas that would otherwise be inaccessible or difficult to fill completely
2Stability of the object's composition
If resin is used to fill the gap between winding portion and magnetic core, then structural integrity is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The outer core portion is segmented to include a through hole, which appears to increase structural complexity but actually simplifies the resin filling process by providing direct access paths, thereby improving structural integrity without proportionally increasing manufacturing complexity
Solution Approach 2:
The outer core portion is designed with a through hole creating a porous or open structure that facilitates resin penetration and filling, enabling complete saturation of the winding portion internal space while maintaining overall structural integrity
Data Source
AI summary
A reactor including: a coil including a winding portion formed by winding a winding wire; and a magnetic core that forms a closed magnetic circuit constituted by an inner core portion located inside the winding portion and an outer core portion located outside the winding portion. The reactor further includes an inner resin portion that fills a gap between the inner circumferential surface of the winding portion and the outer circumferential surface of the inner core portion, and when a side, of the outer core portion, that faces the inner core portion is defined as an inner side, and the opposite side is defined as an outer side, the outer core portion is provided with a through hole that is open to both the inner side and the outer side, and the through hole is filled with a portion of the inner resin portion.