U-Shaped Magnetic Core Reactor for Compact DC-DC Converters
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Solution Overview
Problem
Conventional reactors for in-vehicle DC-DC converters face challenges in achieving a small installation area, low loss, and high productivity due to independent core pieces and gaps that increase manufacturing complexity and magnetic flux leakage.
Innovation Solution
A reactor design featuring a U-shaped magnetic core with integrated side extension and central protruding portions, which reduces the axial length of the winding portions, eliminates gaps between core pieces, and simplifies assembly, thereby minimizing installation area and loss while enhancing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If end core pieces and middle core pieces are made as independent members to simplify their shapes, then manufacturing of individual core pieces becomes easier, but the number of assembling components increases and productivity decreases
Solution Approach 1:
The patent combines multiple core pieces (end core pieces and middle core pieces) into a single integrated core structure. This merging eliminates the need for separate assembly of multiple independent core pieces, thereby reducing the number of assembling components and steps while maintaining manufacturing simplicity through the use of powder compact material.
2Ease of manufacture
If gaps are provided between end core pieces and middle core pieces for assembly, then assembly becomes possible, but magnetic flux leaks from gap portions to protruding portions causing loss such as copper loss to increase
Solution Approach 1:
The patent eliminates gaps between core pieces by integrating them into a single continuous magnetic core structure. This merging ensures magnetic flux continuity, preventing flux leakage from gap portions to protruding portions, thereby reducing copper loss and improving energy efficiency.
3Area of stationary object
If end core pieces protrude further than middle core pieces to reduce installation surface area, then the reactor installation area decreases, but the number of assembling steps increases and productivity decreases
Solution Approach 1:
The patent integrates the protruding portions into a single unified core structure rather than creating them as separate assembly steps. This merging maintains the compact installation footprint while eliminating the need for multiple assembly operations, thereby improving productivity.
4Ease of manufacture
If a uniform flat surface is used for joining core pieces, then manufacturing is simplified, but positioning difficulty increases and productivity decreases
Solution Approach 1:
The patent creates a monolithic core structure where positioning is inherent to the single-piece construction. This eliminates the positioning challenges associated with joining multiple separate core pieces, while the manufacturing simplicity is maintained through powder compact fabrication methods.
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 reactor achieves a smaller installation area, reduced losses from magnetic flux leakage, and improved manufacturing efficiency by integrating core pieces and eliminating gaps, resulting in a more compact and efficient design.
Implementation Method 1
a magnetic core having a U-shaped core piece that is part of a powder compact
Implementation Method 2
A reactor is one type of component of a circuit for increasing or reducing voltage
Data Source
AI summary
Provided is a reactor having a small installation area, low loss, and excellent productivity. The reactor includes a coil having a pair of winding portions and that are arranged side by side, and a magnetic core having a U-shaped core piece that is part of a powder compact. The U-shaped core piece includes a side base that has a portion opposite the ends of the pair of winding portions and uncovered by the winding portions, and disposed across the pair of winding portions, a pair of middle portions that protrude from the side base and respectively disposed inside the pair of winding portions, and an end surface facing a gap, a side extension portion extending from the side base orthogonally from the middle portions, and a central protruding portion protruding from the side base's central region, and are arranged side by side, away from the middle portions.