Roughened Composite Magnetic Core Surface for Stronger Reactor Adhesion
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Solution Overview
Problem
The existing reactors face issues with adhesion between the composite material molded articles used in magnetic cores and other constituent members, leading to potential insulation deterioration, increased vibration, and noise due to thermal expansion and contraction differences.
Innovation Solution
A composite material molded article with a roughened region having an arithmetic average roughness of 3.0 μm or more is used, incorporating soft magnetic powder and resin, where the temperature difference between the melted resin and the mold during manufacturing is 200° C. or higher, enhancing anchor effects and adhesion to other constituents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a smooth surface is used on the composite material molded article, then the manufacturing process is simpler, but the adhesion to other constituent members deteriorates
Solution Approach 1:
The invention changes the surface roughness parameter from smooth to specifically rough (Ra of 3.0 μm or more), which fundamentally alters the adhesion mechanism. The rough surface increases the surface area and creates mechanical interlocking with other constituent members, thereby improving adhesion strength without adding complex manufacturing steps.
2Ease of manufacture
If the composite material molded article has poor adhesion, then the manufacturing process is simpler, but insulation deterioration and vibration increase occur
Solution Approach 1:
By changing the surface roughness parameter to Ra of 3.0 μm or more, the invention creates strong mechanical interlocking that prevents separation between the magnetic core and other constituent members. This eliminates the harmful effects of insulation deterioration and vibration that would otherwise occur due to poor adhesion and thermal expansion differences.
3Reliability
If a roughened region with Ra of 3.0 μm or more is provided on the composite material molded article, then the adhesion to other members is improved, but the manufacturing precision requirement increases
Solution Approach 1:
The invention utilizes the natural cooling and solidification process of the resin during injection molding to self-form the roughened surface. The temperature difference between the melted resin and the mold causes the resin to contract and form a rough surface texture, eliminating the need for separate surface treatment processes while achieving the required Ra of 3.0 μm or more.
4Reliability
If the temperature difference between melted resin and mold is increased to 200° C. or more, then the roughened surface and adhesion are improved, but the energy consumption increases
Solution Approach 1:
The invention optimizes the temperature difference parameter to be 200° C. or more, which is sufficient to create the desired roughened surface and strong adhesion through mechanical interlocking. This parameter setting balances energy consumption with adhesion performance, avoiding excessive heating while achieving the required surface roughness and bonding strength.
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 solution achieves improved adhesion between the magnetic core and other members, reducing vibration and noise by enhancing the anchor effect and ensuring better thermal stability and insulation.
Implementation Method 1
a roughened region having an arithmetic average roughness Ra of 3.0 μm or more is provided on at least a portion of surfaces
Implementation Method 2
a difference Tr−Td between a temperature Tr of the melted resin and a temperature Td of the mold is 200° C. or higher
Data Source
AI summary
Provided is a composite material molded article including soft magnetic powder and resin containing the soft magnetic powder in a dispersed state. The composite material molded article is provided with a roughened region having an arithmetic average roughness Ra of 3.0 μm or more on at least a portion of its surfaces.