Reactor End Surface Interposed Members with Turn Storage
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Solution Overview
Problem
Existing reactors face issues with resin leakage from the end surface interposed members to the axial direction end surfaces of the coil, leading to insufficient resin filling and instability of the inner core portions, which can result in noise and contact between the inner core and winding portions.
Innovation Solution
The reactor design incorporates end surface interposed members with turn storage portions that store the axial direction end portions of the winding, preventing resin leakage by allowing surface contact and ensuring sufficient resin filling between the inner and outer circumferential surfaces, thereby stabilizing the inner core within the winding portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If end surface interposed members are used to ensure insulation between coil and magnetic core, then insulation reliability is improved, but resin leakage occurs from the interface between end surface interposed members and coil end surfaces
Solution Approach 1:
The turn storage portions are formed in advance on the end surface interposed members to store the end portions of winding portions before resin filling. This preliminary structural preparation prevents resin leakage by ensuring proper contact and positioning, eliminating the need for additional sealing actions during the resin filling process.
2Strength
If resin is filled to ensure sufficient bonding between inner core portions and winding portions, then bonding strength is improved, but resin leakage occurs to the outside of winding portions
Solution Approach 1:
The turn storage portions are formed in advance on the end surface interposed members to store the end portions of winding portions. This preliminary structural preparation creates a containment structure that allows sufficient resin filling for strong bonding while preventing resin from leaking outside the winding portions.
3Stability of the object's composition
If inner core portions are held securely within winding portions, then stability is improved, but complexity increases due to additional structural components
Solution Approach 1:
The end surface interposed members serve multiple functions: they provide insulation between the coil and magnetic core, store the end portions of winding portions in their turn storage portions, and prevent resin leakage. By combining these functions into a single component, the need for additional separate structural elements is eliminated, maintaining simplicity while achieving secure holding of inner core portions.
Data Source
AI summary
Provided is a reactor including: a coil having winding portions formed by winding a wire; a magnetic core that forms a closed magnetic circuit with inner core portions arranged inside of the winding portions and outer core portions arranged outside of the winding portions; end surface interposed members that are interposed between axial direction end surfaces of the winding portions and the outer core portions; and an inner resin portion that fills spaces between inner circumferential surfaces of the winding portions and outer circumferential surfaces of the inner core portions, the end surface interposed members including turn storage portions that store at least a portion of turns of the axial direction end portions of the winding portions.