Bobbin wound electrical reactor assembly

1. A reactor assembly comprising:

a first core comprising a plurality of stacked E-shaped planar metal laminates welded together to form a singular unit, wherein the first core further includes a plurality of legs having bottom surfaces and the plurality of legs extend perpendicularly from a top support portion, and wherein the plurality of legs includes a first outer leg, a second outer leg, and a center leg;

a bobbin assembly comprising a plurality of bobbins each having wire windings thereon and a hollow inner cavity, the plurality of bobbins including a first outer bobbin, a second outer bobbin, and a center bobbin, wherein each of the plurality of bobbins receives therein one of the plurality of legs; and wherein a terminal block is provided atop the plurality of bobbins and interconnected with the wire windings;

a second core comprising a plurality of stacked I-shaped planar metal laminates welded together to form a singular unit, the second core including a top surface and a bottom surface, wherein the top surface receives thereon the plurality of bobbins;

a mounting foot secured to the bottom surface of the second core, wherein the mounting foot includes a plurality of latching tabs; and

a U-shaped spring clip that includes a pair of clip arms that each have an inside surface and a tab aperture, wherein the spring clip extends over an upper surface of the top support portion of the first core, and a first of the pair of clip arms extends downward through the inner cavity of the first outer bobbin and a second of the pair of clip arms extends downward through the inner cavity of the second outer bobbin, and wherein the tab apertures are engaged with the latching tabs to secure the spring clip to the mounting foot.

2. The reactor assembly of claim 1 , wherein the first of the pair of clip arms that extends downward through the inner cavity of the first outer bobbin is parallel with and in abutment with a first outer wall that extends along the first outer leg, and the second of the pair of clip arms that extends downward through the inner cavity of the second outer bobbin is parallel with and in abutment with a second outer wall that extends along the second outer leg.

3. The reactor assembly of claim 2 , wherein the plurality of legs each include a leg length, and the plurality of bobbins each include a bobbin length that exceeds the leg length.

4. The reactor assembly of claim 3 , wherein a structural adhesive is applied to least part of the reactor gap that extends between the first core and the second core.

5. The reactor assembly of claim 4 , wherein a structural adhesive is a single part heat cure epoxy.

6. The reactor assembly of claim 5 , further including a terminal block cover secured to the terminal block.

7. The reactor assembly of claim 6 , wherein the terminal block cover includes a plurality of outwardly extending phase-to-phase electrical barriers.

8. The reactor assembly of claim 1 where a separate terminal block is provided for each bobbin, and wherein the terminal blocks are separated by a distance sufficient to provide phase-to-phase voltage clearance.

9. A reactor assembly comprising:

an E-core formed of a plurality of stacked E-shaped planar metal laminates welded together to form a unit, the E-core having a plurality of legs with bottom surfaces, the plurality of legs extending perpendicularly from a top support portion, wherein the plurality of legs includes a first outer leg, a second outer leg, and a center leg;

a plurality of bobbins each having wire windings thereon and a hollow internal bobbin cavity, the plurality of bobbins including a first outer bobbin, a second outer bobbin, and a center bobbin, each of the bobbin cavities receives therein a respective one of the plurality of legs;

a terminal block positioned atop the plurality of bobbins and connected to the wire windings;

an I-core formed of a plurality of stacked I-shaped planar metal laminates welded together to form a unit, the I-core including a top surface and a bottom surface, the top surface receives thereon the plurality of bobbins;

a mounting foot secured to the bottom surface of the I-core;

a plurality of latching tabs formed on the mounting foot; and

a U-shaped spring clip having a pair of clip arms spaced apart from each other, each clip arm having an inside surface and a tab aperture, the spring clip extends over an upper surface of the top support portion of the E-core, a first of the pair of clip arms extending downward through the inner cavity of the first outer bobbin and a second of the pair of clip arms extending downward through the inner cavity of the second outer bobbin, and the tab apertures to engage with the latching tabs to secure the spring clip to the mounting foot;

wherein the first of the pair of clip arms that extends downward through the inner cavity of the first outer bobbin is parallel with and in abutment with a first outer wall that extends along the first outer leg, and the second of the pair of clip arms that extends downward through the inner cavity of the second outer bobbin is parallel with and in abutment with a second outer wall that extends along the second outer leg.

10. The reactor assembly of claim 9 , wherein the plurality of legs have a uniform leg length, and the plurality of bobbins have a uniform bobbin length, and wherein the bobbin length exceeds the leg length, whereby a reactor gap is formed in the reactor assembly between the E-core and the I-core.

11. The reactor assembly of claim 10 , wherein a structural adhesive is applied to at least part of the reactor gap.

12. The reactor assembly of claim 11 , wherein the structural adhesive is a single-part heat cure epoxy.

13. The reactor assembly of claim 12 , further comprising a terminal block cover secured to the terminal block.

14. The reactor assembly of claim 13 , wherein the terminal block cover includes a plurality of outwardly extending phase-to-phase electrical barriers.