Method for manufacturing a magnetic element

Abstract

The present invention provides a method for manufacturing a magnetic component, comprising the following steps: S1, forming a monolithic magnetic component of a desired shape; S2, sequentially cutting both sides of the monolithic magnetic component to form segmented magnetic components, wherein before each side of the monolithic magnetic component is cut, the other side of the monolithic magnetic component is integral. This prevents the monolithic magnetic component from falling apart, omits the subsequent splicing of the magnetic segments, improves the molding efficiency of the segmented magnetic component, ensures product consistency, and facilitates automated production.

Description

Technical Field

[0001] The present invention relates to the technical field of magnetic elements, and in particular to a method for manufacturing a magnetic element. Background Art

[0002] Electromagnetic devices are used to generate electromagnetic forces to achieve their intended purpose. They are categorized into motors and electromagnets, among others. For example, a motor consists of a rotating part called a rotor and a stationary part called a stator. The stator and rotor combine to generate torque. Generally speaking, the stator of a motor consists of an iron core and windings that receive current for operation. The rotor is equipped with multiple magnets. The stator and rotor interact to rotate relative to the stator.

[0003] When magnetic components such as magnets move in a non-uniform magnetic field or are in a magnetic field that changes with time, the induced current in the magnetic component causes energy loss, which is called eddy current loss. Eddy current loss will cause the magnetic component to heat up, thereby affecting the operating performance of the motor.

[0004] The most common way to reduce eddy current loss is to segment the magnetic segments, and then stack the segmented magnetic segments (such as silicon steel sheets) to form a magnetic element. In this process, the multiple magnetic segments obtained by cutting need to be spliced ​​in a preset order, and adhesives are added between two adjacent magnetic segments one by one to form a magnetic element. Not only is the production process cumbersome, time-consuming and labor-intensive, but the manufacturing cost is significantly increased. In addition, after the existing magnetic segments are cut, the cut surface needs to be polished, and then an adhesive is added between the polished cut surfaces of the two magnetic segments to achieve bonding between the two magnetic segments. Therefore, a lot of waste is generated during the magnetic segment molding process, resulting in low material utilization. Summary of the Invention

[0005] The purpose of the present invention is to overcome the above-mentioned shortcomings of the prior art and provide a method for manufacturing a magnetic component that effectively improves the manufacturing efficiency. The purpose of the present invention can be achieved through the following technical solutions:

[0006] A method for manufacturing a magnetic element comprises the following steps:

[0007] S1. Make an integral magnetic component of the desired shape;

[0008] S2. Cutting the two sides of the integral magnetic element in sequence to produce segmented magnetic elements, and before cutting each side of the integral magnetic element, the other side of the integral magnetic element is integral.

[0009] As a preferred embodiment, step S2 includes:

[0010] Glue is injected into a gap formed by cutting on one side of the integral magnetic element, so that the side of the integral magnetic element where the glue injection gap is located is formed into one piece.

[0011] As a preferred embodiment, step S2 includes:

[0012] S21, cutting a reserved margin on one side of the integral magnetic component, and injecting glue into a first gap formed by the cutting;

[0013] S22 , cutting is performed on the other side of the integral magnetic component to form a second gap intersecting with the first gap, and glue is injected into the second gap.

[0014] As a preferred embodiment, in the step S21, a plurality of the first gaps are simultaneously cut on one side of the integral magnetic element, and the plurality of the first gaps are arranged at intervals along the radial direction of the integral magnetic element; and then in the step S22, a plurality of the second gaps are simultaneously cut on the other side of the integral magnetic element, and the second gaps correspond to the first gaps one by one.

[0015] As a preferred embodiment, the first gap and the second gap are respectively provided on two axial or circumferential sides of the integral magnetic element 200 .

[0016] As a preferred embodiment, before each glue injection, the method further comprises:

[0017] The surface of the cut integral magnetic element is cleaned.

[0018] As a preferred embodiment, the first slit and the second slit are located on the same straight line;

[0019] Alternatively, the first slit and the second slit are arranged at an angle;

[0020] Alternatively, the second gap includes a straight side and a hypotenuse, the straight side is parallel to the first gap, and the hypotenuse is obliquely connected between the straight side and the first gap.

[0021] As a preferred embodiment, the width of the first gap and the second gap ranges from 0.05 to 0.2 mm.

[0022] As a preferred embodiment, the overall magnetic element has a fan-shaped, rectangular or trapezoidal shape.

[0023] As a preferred embodiment, the integral magnetic element is made of permanent magnet material.

[0024] Compared with the existing technology, this technical solution has the following advantages:

[0025] First, before cutting each side of the integral magnetic element, ensure that the other side of the integral magnetic element is integrated, so as to avoid the overall magnetic element from falling apart, and facilitate the cutting and formation of the gap on the other side of the integral magnetic element, and can directly produce a segmented magnetic element. Compared with the traditional manufacturing method, the subsequent splicing process of each magnetic segment is omitted, thereby improving the molding efficiency of the segmented magnetic element.

[0026] Second, glue injection is used to ensure that the other side of the integral magnetic element is integrated, while ensuring insulation between the magnetic segments formed by cutting, and at the same time ensuring the overall strength of the segmented magnetic element.

[0027] Third, the grinding process is omitted, which not only improves the molding efficiency, but also avoids the problem of low material utilization caused by grinding.

[0028] Fourth, it can ensure product consistency and is conducive to automated production.

[0029] The present invention is further described below with reference to the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is a schematic diagram of a cut side of the integral magnetic element of the present invention;

[0031] Figure 2 This is a schematic structural diagram of a first embodiment of the segmented magnetic element of the present invention;

[0032] Figure 3 Schematic diagram of the structure of the second embodiment of the segmented magnetic element of the present invention;

[0033] Figure 4 Schematic diagram of the structure of the third embodiment of the segmented magnetic element of the present invention.

[0034] In the figure: 100a is an integral magnetic element, 100b is a segmented magnetic element, 110 is a magnetic segment, 1000 is a gap, 1001 is a first gap, 1002 is a second gap, 10021 is a straight edge, and 10022 is a bevel edge. DETAILED DESCRIPTION

[0035] The following description is intended to disclose the present invention so that those skilled in the art can implement the present invention. The preferred embodiments described below are for illustrative purposes only, and those skilled in the art will readily appreciate other obvious variations. The basic principles of the present invention defined in the following description may be applied to other embodiments, variations, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the present invention.

[0036] like Figure 1 and Figure 2As shown, the manufacturing method of the magnetic element comprises the following steps:

[0037] S1. Manufacturing an integral magnetic element 100a of a desired shape;

[0038] S2. Cutting the two sides of the integral magnetic element 100a in sequence to produce segmented magnetic elements 100b. Before cutting each side of the integral magnetic element 100a, the other side of the integral magnetic element 100a is integral.

[0039] By cutting both sides of the integral magnetic element 100a to form a gap 1000 running through the integral magnetic element 100a, the integral magnetic element 100a is segmented to form a plurality of magnetic segments 110 radially arranged along the integral magnetic element 100a, thereby producing the segmented magnetic element 100b. It can be seen that the gap 1000 running through the integral magnetic element 100a is formed by two cuts, wherein before cutting each side of the integral magnetic element 100a, the other side of the integral magnetic element 100a is ensured to be integral, thereby preventing the integral magnetic element 100a from falling apart and facilitating the cutting and forming of the gap on the other side of the integral magnetic element 100a. Furthermore, the segmented magnetic element 100b can be directly produced. Compared with traditional manufacturing methods, the subsequent splicing process of the magnetic segments 110 is omitted, thereby improving the molding efficiency of the segmented magnetic element 100b, and at the same time ensuring product consistency, which is conducive to automated production.

[0040] In step S1, the shape of the integral magnetic element 100a determines the shape of the resulting segmented magnetic element 100b. The integral magnetic element 100a can be regular or irregular in shape. A regular shape includes a cross-sectional shape of the integral magnetic element 100a that is fan-shaped, rectangular, or trapezoidal. When the cross-sectional shape of the integral magnetic element 100a is fan-shaped and the axial dimension (thickness) of the integral magnetic element 100a is small, the resulting segmented magnetic element 100b can be used in, for example, the stator core of an axial magnetic field motor.

[0041] The integral magnetic element 100a may be made of a permanent magnet material having a certain electrical conductivity and may be manufactured by powder metallurgy. The permanent magnet material includes but is not limited to neodymium iron boron, aluminum nickel cobalt, samarium cobalt, and the like.

[0042] In step S2, the two sides of the integral magnetic element 100a are cut to form gaps 1000 that block the transmission path of the eddy current, thereby reducing the eddy current loss and effectively avoiding the temperature rise caused by the eddy current loss, thereby preventing the demagnetization of the magnetic segment 110 and affecting its service life. Figure 1 and Figure 2 , the step S2 comprises:

[0043] S21, cutting a reserved margin on one side of the integral magnetic element 100a, and injecting glue into the first gap 1001 formed by cutting;

[0044] S22 , cutting is performed on the other side of the integral magnetic element 100 a to form a second gap 1002 intersecting with the first gap 1001 , and glue is injected into the second gap 1002 .

[0045] The first gap 1001 and the second gap 1002 intersect and are connected to form a gap 1000 that separates the integral magnetic element 100a. It can be seen that the gap 1000 is formed by secondary cutting. In the step S21, the right side of the integral magnetic element 100a is cut to form the first gap 1001. At this time, a margin is reserved from the first gap 1001 to the left side of the integral magnetic element 100a, that is, the left side of the integral magnetic element 100a is integrated, that is, when the first gap 1001 is cut, the integral magnetic element 100a will not be segmented. In addition, in the step S21, glue is injected into the first gap 1001 to make the right side of the integral magnetic element 100a after cutting integral, so that the left side of the integral magnetic element 100a can be cut in the step S22, and the integral magnetic element 100a will not be segmented in the process, thereby omitting the subsequent splicing process.

[0046] In addition, after the first gap 1001 and the second gap 1002 are formed by cutting the overall magnetic element 100a, glue is injected into the first gap 1001 and the second gap 1002 at the same time. Similar to the traditional production method, the grinding process is omitted, which not only improves the molding efficiency, but also avoids the problem of low material utilization rate caused by grinding. It is further explained that in the traditional production method, in order to achieve the bonding effect between each magnetic segment 110, it is necessary to grind the cut surface. However, in the present application, when each side of the overall magnetic element 100a is cut, the other side of the overall magnetic element 100a is integrated to prevent the situation where bonding cannot occur.

[0047] The width of the first gap 1001 and the second gap 1002 ranges from 0.05 to 0.2 mm, where the width refers to the radial dimension of the first gap 1001 and the second gap 1002 on the integral magnetic element 100a. It should be noted that the width dimensions of the first gap 1001 and the second gap 1002 may be the same or different.

[0048] The glue may be an insulating adhesive to ensure insulation between the magnetic segments 110 and reliable bonding, and to ensure the overall strength of the segmented magnetic element 100 b.

[0049] like Figure 2 As described above, the first gap 1001 and the second gap 1002 are located on both sides of the circumference of the integral magnetic element 100a. Of course, the first gap 1001 and the second gap 1002 are located on both sides of the axial direction of the integral magnetic element 100a, and can be designed according to actual needs.

[0050] Prior to the glue injection, the method further includes: cleaning the surface of the cut integral magnetic element 100a, including using a cleaning medium or blowing air to remove cutting impurities on the surface of the integral magnetic element 100a. It is worth noting that using a cleaning medium (especially a liquid) requires that the surface be dried before the glue is injected into the gap.

[0051] For example, in step S21 , when the first gap 1001 is cut and formed, the surface of the integral magnetic element 100a can be cleaned with a cleaning liquid to flush out cutting impurities on the surface of the integral magnetic element 100a , and then glue is injected into the first gap 1001 after drying.

[0052] Similarly, in step S22 , after the second gap 1002 is cut and formed, the surface of the integral magnetic element 100 a can be cleaned with a cleaning liquid to flush out cutting impurities on the surface of the integral magnetic element 100 a , and then glue is injected into the second gap 1002 after drying.

[0053] Since the first gap 1001 and the second gap 1002 are connected, the glue in the first gap 1001 and the second gap 1002 are integrated to block the two adjacent magnetic segments 110, thereby obtaining a segmented magnetic element 100b.

[0054] The shape of the gap 1000 can be varied, and is described below through three embodiments:

[0055] In one embodiment, the first slit 1001 and the second slit 1002 are located on the same straight line, so that the slit 1000 is a straight line. Figure 2 .

[0056] In another embodiment, the first slit 1001 and the second slit 1002 are arranged at an angle to form Figure 3 The shape of the gap 1000 is shown. The angle between the first gap 1001 and the second gap 1002 is between 120 and 180 degrees.

[0057] In another embodiment, the second gap 1002 includes a straight edge 10021 and a bevel 10022, the straight edge 10021 is parallel to the first gap 1001, and the bevel 10022 is obliquely connected between the straight edge 10021 and the first gap 1001 to form a Figure 4 The length of the straight edge 10021 is close to the length of the first gap 1001, while the length of the oblique edge 10022 is shorter and only serves to connect the straight edge 10021 and the first gap 1001.

[0058] like Figures 2 to 4 As shown, the segmented magnetic element 100b includes a plurality of magnetic segments 110, which are arranged radially along the segmented magnetic element 100b, and a bonding glue is provided between two adjacent magnetic segments 110. The bonding glue is formed by drying the injected glue. When the segmented magnetic element 100b is fan-shaped, the width of each magnetic segment 110 gradually decreases from top to bottom along the radial direction. Figure 2 The radial upper side of the segmented magnetic element 100b is convex, and the radial lower side of the segmented magnetic element 100b is concave. Furthermore, the shape of the magnetic segments 110 along the radial sides of the integral magnetic element 100a is determined by the gap 1000. For example, when the gap 1000 is a straight line, the magnetic segments 110 along the radial sides of the integral magnetic element 100a are straight lines.

[0059] Said sequential cutting on both sides of the integral magnetic element 100a means that the integral magnetic element 100a may be cut once on one side and then cut once on the other side of the integral magnetic element 100a to form an intersecting first gap 1001 and second gap 1002. Of course, it is also possible to cut a plurality of first gaps 1001 on one side of the integral magnetic element 100a and then cut a plurality of second gaps 1002 on the other side of the integral magnetic element 100a, and the first gaps 1001 and the second gaps 1002 correspond to each other and intersect.

[0060] Specifically, the right side of the integral magnetic element 100a is cut once to form the first gap 1001 and injected with glue, and then one side of the left side of the integral magnetic element 100a is cut to form the second gap 1002 and injected with glue. This cycle is repeated to form a plurality of first gaps 1001 and a plurality of second gaps 1002 on the integral magnetic element 100a, and the first gaps 1001 and the second gaps 1002 correspond to each other one by one and intersect.

[0061] Alternatively, in step S2, a plurality of first gaps 1001 can be cut on the right side of the integral magnetic element 100a at the same time, and the plurality of first gaps 1001 are arranged at intervals along the radial direction of the integral magnetic element 100a, and then glue is injected into each of the first gaps 1001 at the same time. Then, a plurality of second gaps 1002 can be cut on the right side of the integral magnetic element 100a at the same time, and the plurality of second gaps 1002 are arranged at intervals along the radial direction of the integral magnetic element 100a, and the first gaps 1001 and the second gaps 1002 on both sides of the integral magnetic element 100a correspond one to one, and the corresponding first gaps 1001 and the second gaps 1002 intersect, which can effectively improve the molding efficiency. After step S2, the method further includes the following steps:

[0062] S3. Clean the residual glue on the surface of the segmented magnetic component 100b to ensure the consistency of product size and avoid the residual glue from restricting its installation.

[0063] Since the present application omits the subsequent splicing process and the gap 1000 is formed by secondary cutting, the integral magnetic element 100a can be fixed by a clamp, for example, the clamp is fixed at the position of the integral magnetic element 100a except for the cutting, and then the left and right sides of the integral magnetic element 100a are cut to form a gap 1000 that passes through the integral magnetic element 100a, and glue is injected into the gap 1000 formed by each cutting, and the above steps can be performed automatically, thereby realizing automated production.

[0064] In summary, before cutting each side of the overall magnetic element 100a, it is ensured that the other side of the overall magnetic element 100a is integrated, so as to avoid the overall magnetic element 100a from falling apart, and to facilitate the cutting and formation of the gap on the other side of the overall magnetic element 100a, and to be able to directly produce the segmented magnetic element 100b. Compared with the traditional manufacturing method, the subsequent process of splicing the magnetic segments 110 is omitted, thereby improving the molding efficiency of the segmented magnetic element 100b. Glue injection is used to ensure that the other side of the overall magnetic element 100a is integrated, while ensuring the insulation between the magnetic segments 110 formed by cutting, and at the same time ensuring the overall strength of the segmented magnetic element 100b. The grinding process is also omitted, which not only improves the molding efficiency, but also avoids the problem of low material utilization caused by grinding. At the same time, it can ensure the consistency of the product, which is conducive to automated production.

[0065] The embodiments described above are only used to illustrate the technical ideas and features of the present invention. Their purpose is to enable those skilled in the art to understand the contents of the present invention and implement them accordingly. The scope of the patent application of the present invention cannot be limited by these embodiments alone. That is, any equivalent changes or modifications made according to the spirit disclosed by the present invention still fall within the patent scope of the present invention.

Claims

1. A method for manufacturing a magnetic element, characterized in that: The following steps are involved: S1. Manufacturing an integral magnetic element (100a) of a desired shape; S2, cutting the two sides of the integral magnetic element (100a) in sequence to produce segmented magnetic elements (100b), and before cutting each side of the integral magnetic element (100a), the other side of the integral magnetic element (100a) is integral; The step S2 comprises: S21, performing a cutting with a reserved margin on one side of the integral magnetic element (100a), and injecting glue into the first gap (1001) formed by the cutting; S22, cutting is performed on the other side of the integral magnetic element (100a) to form a second gap (1002) intersecting with the first gap (1001), and glue is injected into the second gap (1002).

2. The method for manufacturing a magnetic element according to claim 1, wherein: The step S2 comprises: Glue is injected into a gap (1000) formed by cutting on one side of the integral magnetic element (100a), so that the side of the integral magnetic element (100a) where the glue-injected gap (1000) is located is formed into one piece.

3. The method for manufacturing a magnetic element according to claim 1, wherein: In the step S21, a plurality of first slits (1001) are simultaneously cut on one side of the integral magnetic element (100a), and the plurality of first slits (1001) are arranged at intervals along the radial direction of the integral magnetic element (100a); and then in the step S22, a plurality of second slits (1002) are simultaneously cut on the other side of the integral magnetic element (100a), and the second slits (1002) correspond to the first slits (1001) one by one.

4. The method for manufacturing a magnetic element according to claim 1, wherein: The first gap (1001) and the second gap (1002) are respectively arranged on both sides of the integral magnetic element (200) in the axial direction or the circumferential direction.

5. The method for manufacturing a magnetic element according to claim 1, wherein: Before each glue injection, the method further comprises: The surface of the cut integral magnetic element (100a) is cleaned.

6. The method for manufacturing a magnetic element according to claim 1, wherein: The first slit (1001) and the second slit (1002) are located on the same straight line; Alternatively, the first slit (1001) and the second slit (1002) are arranged at an angle; Alternatively, the second gap (1002) includes a straight edge (10021) and a hypotenuse (10022), the straight edge (10021) is parallel to the first gap (1001), and the hypotenuse (10022) is obliquely connected between the straight edge (10021) and the first gap (1001).

7. The method for manufacturing a magnetic element according to claim 1, wherein: The width of the first gap (1001) and the second gap (1002) ranges from 0.05 to 0.2 mm.

8. The method for manufacturing a magnetic element according to claim 1, wherein: The overall magnetic element (100a) has a fan-shaped, rectangular or trapezoidal shape.

9. The method for manufacturing a magnetic element according to claim 1, wherein: The integral magnetic element (100a) is made of permanent magnet material.

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