Self-Fusing Coil Reactor Vibration Damping
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Solution Overview
Problem
Conventional reactors without fillers experience vibrations and noise generation due to coil vibrations, leading to stress on the connection portion between the coil and the electric circuit, which can result in breakdowns over time, and they lack efficient cooling mechanisms.
Innovation Solution
A reactor design featuring a self-fusing coil with a conductive wire coated in a thermosetting resin, integrated with a resin cover using an adhesive, eliminating the need for fillers and allowing direct contact with cooling media, thereby reducing vibrations, noise, and stress on the connection points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If filler is used to eliminate gaps between coil and resin cover, then vibration and noise are suppressed, but cooling efficiency deteriorates due to blocked heat dissipation paths
Solution Approach 1:
The invention removes the filler material from the reactor structure, extracting the harmful element that blocked cooling paths while addressing vibration issues through alternative means (coil integration and resin cover design)
Solution Approach 2:
The invention changes the physical state and properties of the coil by applying resin coating and heating treatment, transforming the coil structure to provide self-damping without requiring filler material, thus enabling both vibration suppression and efficient cooling
2Temperature
If filler is eliminated to improve cooling efficiency, then heat dissipation is enhanced, but vibration and noise generation increases due to lack of damping
Solution Approach 1:
The coil structure serves dual functions: it acts as the electrical conductor and simultaneously provides vibration damping through the resin coating and integrated structure, eliminating the need for separate filler material
Solution Approach 2:
The invention creates a composite structure by coating the coil with resin material and applying heating treatment, forming an integrated coil-resin composite that provides both electrical functionality and vibration damping properties
3Temperature
If coil is exposed to cooling medium without filler, then cooling efficiency is improved, but stress on connection portions increases due to coil vibrations
Solution Approach 1:
The resin coating is applied to the coil beforehand to provide cushioning and damping protection against vibrations that would otherwise transmit stress to connection portions during operation
Solution Approach 2:
Heating treatment is applied to change the physical properties of the resin coating, enhancing its damping characteristics and bonding strength to protect connection portions from vibration-induced stress
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
The integration of the self-fusing coil with the resin cover suppresses coil vibrations and noise, reduces stress on the connection points, and enhances cooling efficiency, resulting in a more reliable and durable reactor.
Implementation Method 1
a self-fusing layer formed on a surface of the conductive wire, the adjoining conductive wire portions being bonded together by the self-fusing layer
Implementation Method 2
the end portion of the coil being bonded with the resin cover by an adhesive at the bonding portion
Data Source
AI summary
A reactor includes a core, a resin cover provided around the core, and a coil disposed around the core at the external side of the resin cover. The coil includes a conductive wire having a self-fusing layer formed on the surface of the conductive wire, and the adjoining conductive wire portions are bonded together by the self-fusing layer. The resin cover includes a bonding portion provided at a part of the resin cover and facing the end portion of the coil, and the end portion of the coil are bonded with the resin cover by an adhesive at the bonding portion.