Production mold and method for new energy synchronous rotor

Abstract

The invention discloses a production mold and method for a new energy synchronous rotor, the production mold comprises an upper mold assembly and a lower mold assembly, and the upper mold assembly sequentially comprises a main nozzle and a nozzle with the top end used for being connected with an external injection molding machine from top to bottom so as to receive a molten rubber material; the splitter plate is internally provided with a plurality of sub-runners which are radially distributed by taking the outlet of the main nozzle as the center, and the inlets of the sub-runners are communicated with the outlet of the main nozzle; the inlets of the branch nozzles are correspondingly connected to the outlets of the branch runners respectively; an inner ring groove, an outer ring groove and a plurality of radial connecting grooves which are communicated with one another are formed in the path plate, so that a closed-loop runner path is formed; by means of the closed-loop runner path plate, glue from the center main nozzle is distributed into an inner ring path and an outer ring path which surround the circumference of the rotor, and in each injection molding period, the volume of residual glue solidified in a path plate channel system is greatly reduced.

Description

Technical Field

[0001] This application belongs to the field of injection mold technology, and in particular relates to a production mold and method for a new energy synchronous rotor. Background Technology

[0002] To achieve higher power density and efficiency, high-performance new energy drive motors commonly employ built-in permanent magnet synchronous rotor technology. Among these, the built-in V-shaped (or double-layer V-shaped) permanent magnet layout has become an industry-recognized advanced design solution. This design embeds strip permanent magnets into the rotor core slots at a specific angle, forming a "V" shape arrangement (often including a combination of large and small V-shapes). Its core advantage lies in its ability to cleverly utilize "reluctance torque" to superimpose with "permanent magnet torque," thereby significantly increasing the total output torque. Simultaneously, it optimizes the air gap magnetic field waveform and reduces torque ripple and iron losses, making it crucial for achieving high-power, high-efficiency, and highly smooth motor operation.

[0003] However, this complex magnetic circuit topology presents significant challenges to its manufacturing process, particularly the fixing and insulation of the magnets. To securely fix the magnets within the V-grooves and ensure reliable insulation, the current mainstream process involves injecting thermoplastic engineering plastic (hereinafter referred to as "plastic material") into the precise gap between the magnets and the iron core grooves. Because the V-grooves of the magnets are distributed in multiple circumferential layers (usually inner and outer layers) on the rotor, and each layer of grooves forms a non-standard annular cavity through the iron core, the cavity system requiring the filling of the plastic material is exceptionally complex.

[0004] Existing filling methods generally employ a single central injection cold runner system. Specifically, after the rubber compound is injected through the main gate at the center of the mold, it passes through a radially distributed runner system to multiple pre-set gate positions in the inner and outer annular cavities. From there, it enters the final magnet gap for filling. This process path suffers from an extremely long runner system, a long rubber flow path, and significant temperature and pressure losses: the flow path from the center to the furthest gate is tortuous and lengthy. The magnet gaps at the end of the runners are prone to incomplete filling, forming voids or weak interfaces. The complex radial runners and the inner and outer annular distribution cavities themselves do not constitute the final product; they only serve to transport the rubber compound. However, in each production cycle, the rubber compound solidified in these massive runner systems becomes "waste material" that must be removed. While this waste can be recycled, it not only increases the cost and energy consumption of crushing, sorting, and reprocessing, but its deteriorated performance also affects the proportion of recycled material added, ultimately increasing overall material costs and generating a large amount of solid waste. This shows that existing technologies need further improvement and enhancement. Summary of the Invention

[0005] This invention provides a production mold and method for a new energy synchronous rotor, which at least solves or alleviates one or more technical problems in the prior art, or at least provides a beneficial alternative.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A production mold for a new energy synchronous rotor includes an upper mold assembly and a lower mold assembly, wherein the upper mold assembly comprises, from top to bottom: The main nozzle, with its tip used to connect to the nozzle of an external injection molding machine to receive molten rubber; The flow divider plate has multiple flow channels radially distributed around the main nozzle outlet, with the inlet of each flow channel connected to the outlet of the main nozzle. Multiple branch nozzles have their inlets connected to the outlets of their respective flow channels. A path plate has interconnected inner and outer annular grooves and multiple radial connecting grooves, forming a closed-loop flow path. The outlets of the multiple branch nozzles are connected to multiple glue inlet points on the closed-loop flow path. Multiple glue injection holes are evenly distributed at the bottom of the inner and outer annular grooves and each radial connecting groove. The lower mold assembly includes a lower mold base for placing the rotor core. When the mold is closed, all the injection holes at the bottom of the path plate are aligned with the gaps between the permanent magnets on the rotor core and the slot walls.

[0007] In a preferred embodiment, the top of the inner annular groove of the path plate is provided with a plurality of circular recesses at even intervals along the circumference. These circular recesses constitute the glue inlet points for the branch nozzle outlets. The vertical projection of the glue inlet points is located in the area covered by the inner annular groove and / or the outer annular groove.

[0008] In a preferred embodiment, the injection holes on the path plate have a cross-sectional shape that gradually narrows from the injection direction to the discharge direction. On the mating surface of the path plate facing the rotor core, a hollow truncated cone is integrally formed for each injection hole. When the mold is closed, the lower end of the hollow truncated cone is inserted into and tightly fitted into the gap entrance between the corresponding permanent magnet and the core slot on the rotor core.

[0009] In a preferred embodiment, the manifold integrates a hot runner system, which includes heating elements embedded in the upper and lower surfaces of the manifold. The main nozzle, the manifold channels in the manifold, and the branch nozzles are all located within the heating temperature zone of the hot runner system, so that the flowing adhesive remains in a molten state.

[0010] In a preferred embodiment, the upper mold assembly further includes an upper mold core, which is fixedly disposed above the path plate, with its lower surface and the upper surface of the path plate jointly sealing the top opening of the flow channel groove; an upper pad plate, which is fixedly disposed above the upper mold core; each of the branch nozzles passes through the upper pad plate and the upper mold core in sequence, and its outlet is connected to the glue inlet point of the path plate; a hollow ejector plate that can move along the mold opening and closing direction is sleeved on the outer periphery of the path plate; under the action of the driving mechanism, the hollow ejector plate can be ejected after the mold is opened and drive the path plate to separate from the upper mold core, so as to open the closed-loop flow channel path.

[0011] In a preferred embodiment, the lower mold base includes a central placement plate and clamping blocks symmetrically arranged on both sides of the placement plate that can move radially. Each clamping block has an oblique hole, and the upper mold assembly is correspondingly provided with an oblique guide post. During the mold closing process, the oblique guide post is inserted into the corresponding oblique hole, driving the two clamping blocks to move towards each other, applying radial extrusion force to the rotor core placed on the placement plate to clamp and fix it.

[0012] In a preferred embodiment, an independent temperature control system is integrated inside the placement tray of the lower mold base; the temperature control system is configured to maintain the temperature of the rotor core within a set temperature range that prevents the adhesive from curing during the adhesive injection process; and to ensure that the rotor core and the adhesive in the gaps cure synchronously and uniformly after all the adhesive has been injected.

[0013] In a preferred embodiment, a sealed vibration chamber is provided inside the clamping block, and an impactor that can roll freely is provided inside the vibration chamber; the impactor moves in the vibration chamber and generates impacts, thereby transmitting vibrations to the rotor core.

[0014] In a preferred embodiment, the lower mold base is provided with two parallel pressure rails, and stepped sliders extend laterally from both sides of the clamping block. The pressure rails are located above the upper step surface of the stepped sliders and maintain a vertical gap with the upper step surface. The lower mold base is also provided with a limiting part, which is located on the opposite side of the two clamping blocks and is used to limit the outward movement of the clamping blocks.

[0015] A method for using a production mold for a new energy synchronous rotor includes the following steps: S1: The rotor core, which has been initially loaded with permanent magnets, is placed on the placement plate of the lower mold base by the robotic arm. The upper mold assembly moves downward, and the inclined guide post on it is inserted into the inclined hole of the clamping block. The clamping block is driven to move along the pressure rail and the step slider guide to radially support and fix the rotor core to the center of the placement plate. S2: The hot runner system is powered on and heated to the melting temperature of the rubber compound. The temperature control system of the placement tray is activated to preheat the rotor core and maintain it at the set temperature. S3: The external injection molding machine injects glue through the main nozzle. The molten glue is distributed to each branch nozzle through the distribution channel. It is injected into the inner ring groove, radial connecting groove and outer ring groove of the injection point through the injection point. It is injected into each gap through all injection holes through the hollow cone. S4: The clamping block's built-in impactor strikes the cavity wall, generating vibration that is transmitted to the rotor, aiding in exhaust and filling; S5: After the glue is injected, pressure is maintained, and the temperature control system of the tray executes the preset program. First, heat is maintained to allow the glue to flow and fuse fully, and then cooling is started to allow the glue in all gaps to cure synchronously and evenly. S6: After curing, all heating systems are turned off, the upper mold moves upward, the inclined guide post drives the clamping block to release the rotor, the hollow ejector plate moves, lifts the path plate to separate it from the upper mold core, opens the closed loop flow path to remove the material, and the robot arm removes the finished rotor.

[0016] The above structure has the following beneficial effects: 1. The production mold for the new energy synchronous rotor of this application distributes the adhesive material from the central main nozzle into the inner and outer double-ring paths surrounding the rotor circumference through a closed-loop flow channel path plate. This allows the adhesive material to be injected at close range from multiple injection holes pre-set directly above each magnet gap, greatly shortening the adhesive material flow path and significantly reducing pressure and temperature losses. This ensures that all gaps, especially the far-end gaps, are uniformly and fully filled, effectively avoiding the generation of voids and weak interfaces. In each injection cycle, the volume of residual adhesive solidified in the path plate channel system is significantly reduced, thereby directly reducing the amount of "waste material" that must be disposed of as waste, improving material utilization, and reducing overall production costs and solid waste.

[0017] 2. The production mold for the new energy synchronous rotor of this application integrates the positioning, clamping, and releasing actions of the rotor into the main mold closing / opening process using the inclined guide column driven internal support clamping mechanism, eliminating the need for secondary operations. Combined with robotic arm loading and unloading, it achieves full automation of the entire process from placement, clamping, gluing, curing to removal, significantly improving production cycle time and continuity.

[0018] 3. In the production mold for the new energy synchronous rotor of this application, the adhesive is injected from the injection hole pre-set above each gap. Combined with the micro-disturbance of vibration, it is ensured that the adhesive can completely fill all the narrow gaps and form a defect-free dense adhesive layer.

[0019] 4. The production mold for the new energy synchronous rotor of this application actively manages the curing process of the adhesive. The system first heats the adhesive to keep it molten and fully fused, and then cools it uniformly to cure it synchronously, completely eliminating the thermal history differences caused by different filling sequences. This ensures that the adhesive layer in all the gaps between the magnets has consistent crystallinity, shrinkage rate and internal stress, avoiding local weak points, and significantly improving the overall fixing strength and insulation reliability. Attached Figure Description

[0020] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this invention, illustrate exemplary embodiments of the invention and, together with their description, serve to explain this application and do not constitute an undue limitation of the invention. In the drawings: Figure 1 A schematic three-dimensional structural diagram of one embodiment of the production mold for the new energy synchronous rotor of this application is shown; Figure 2 The diagram illustrates a schematic embodiment of the flow divider plate inside the mold base in this application. Figure 3 A schematic three-dimensional structural diagram of one embodiment of the diversion plate of this application is shown; Figure 4 The diagram illustrates a cross-sectional view of one embodiment of the present application, in which the branch nozzle passes through the upper pad and the upper mold core mates with the path plate. Figure 5 A schematic three-dimensional structural diagram illustrating one embodiment of the path plate of this application with a path groove is shown. Figure 6 A schematic three-dimensional structural diagram illustrating one embodiment of the hollow truncated cone setting in the path plate of this application is shown. Figure 7 A schematic three-dimensional structural diagram illustrating one embodiment of the mold core and the target of this application is shown. Figure 8 A schematic three-dimensional structural diagram illustrating one embodiment of the upper mold component of this application is shown; Figure 9 A schematic three-dimensional structural diagram illustrating one embodiment of the lower mold component of this application is shown; Figure 10 A schematic three-dimensional structural diagram illustrating one embodiment of the step slider and pressure rail cooperation of this application is shown; Figure 11 A schematic diagram illustrating the internal structure of one embodiment of the internal vibration chamber and impactor of the clamping block in this application is shown. Label Explanation: 10. Upper mold base; 11. Manifold plate; 110. Manifold channel; 111. Heating element; 12. Upper backing plate; 13. Upper mold core; 14. Path plate; 140. Inner ring groove; 141. Outer ring groove; 142. Radial connecting groove; 143. Injection point; 144. Injection hole; 145. Hollow truncated cone; 15. Ejector plate; 150. Angled guide post; 16. Main nozzle; 17. Branch nozzle; 20. Lower mold base; 200. Clearance hole; 21. Placement plate; 22. Clamping block; 220. Angled hole; 221. Stepped slider; 222. Vibration chamber; 223. Impact body; 23. Pressure rail; 24. Limiting part; 30. Rotor core; 31. Magnet; 310. Filler gap; 4. Material sludge. Detailed Implementation

[0021] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit and scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0022] The present invention will now be described with reference to the accompanying drawings.

[0023] The specific solution adopted is as follows: like Figure 1-11 As shown, the present invention provides a production mold for a new energy synchronous rotor, comprising an upper mold assembly and a lower mold assembly, wherein the upper mold assembly comprises, from top to bottom: The main nozzle 16 has a top end for connecting to the nozzle of an external injection molding machine to receive molten rubber. The flow divider 11 has multiple flow dividers 110 arranged radially around the outlet of the main nozzle 16. The inlets of the flow dividers 110 are all connected to the outlet of the main nozzle 16. Multiple branch nozzles 17, the inlet of each branch nozzle 17 being respectively connected to the outlet of each of the branch channels 110; The path plate 14 has a connected inner ring groove 140, an outer ring groove 141 and a plurality of radial connecting grooves 142 to form a closed-loop flow path; the outlets of the plurality of branch nozzles 17 are respectively connected to a plurality of glue inlet points 143 on the closed-loop flow path; a plurality of glue injection holes 144 are evenly distributed at the bottom of the inner ring groove 140, the outer ring groove 141 and each radial connecting groove 142. The lower mold assembly includes a lower mold base 20 for placing the rotor core 30. When the mold is closed, all the injection holes 144 at the bottom of the path plate 14 are aligned with the gaps between the permanent magnets and the slot walls on the rotor core 30.

[0024] The production mold for the new energy synchronous rotor of this application is a composite scheme of annular flow distribution and multi-point synchronous injection. In the traditional scheme, the rubber material flows a long distance from the central main gate to the radial flow channels 110 and then to the far gate in a complex cavity. In this scheme, the rubber material is directly injected into the closed-loop flow path from the central main nozzle 16 to the radial flow channels 110 and then to the branch nozzles 17. The closed-loop flow path, namely the inner ring groove 140, the outer ring groove 141, and the radial connecting groove 142, acts as a pre-filled distribution ring. Once the rubber material enters this ring, it can be injected into the gap of the magnet 31 directly below it through the various injection holes 144 on the ring with the shortest path. This unifies and shortens the tortuous, long, and variable process from the center to the end of the gap of the magnet 31 in the traditional scheme into a short and direct vertical injection from the distribution ring to the gap of the magnet 31. This significantly reduces flow resistance, and the pressure and temperature of the rubber material can be more efficiently preserved before final filling.

[0025] Traditional solutions utilize a large radial distribution channel system 110 and inner / outer ring distribution chambers, which are cold runners. During each cycle, these cold runners solidify, forming material residue 4 that must be removed. In contrast, this solution's main nozzle 16, distributor plate 11, and branch nozzles 17 are all hot runner systems, ensuring the internal material remains molten and produces no solid waste. The only solid flow path is the closed-loop flow path on the path plate 14. This improves material utilization, significantly reduces material costs, and minimizes recycling and solid waste.

[0026] Furthermore, the manifold 11 integrates a hot runner system, which includes heating elements 111 embedded in the upper and lower surfaces of the manifold 11. The main nozzle 16, the manifold channel 110 in the manifold 11, and the branch nozzle 17 are all located within the heating temperature zone of the hot runner system, so that the flowing adhesive always remains in a molten state.

[0027] In summary, the improvement is comprehensive, from "vertical injection cold runner, radial flow splitting, and a large amount of material 4" to multi-point hot runner, annular path distribution, and reduced material 4. There is no need to cool and remove the large and cumbersome material 4, the cooling time can be shortened, and the mold opening and closing stroke can also be optimized, thereby speeding up the production pace.

[0028] As a preferred embodiment of this application, see [link to application]. Figure 5 The top of the inner annular groove 140 of the path plate 14 is provided with a plurality of circular recesses evenly spaced along the circumference. These circular recesses constitute the glue inlet 143 at which the outlet of the branch nozzle 17 is connected. The vertical projection of the glue inlet 143 is located in the area covered by the inner annular groove 140 and / or the outer annular groove 141.

[0029] By creating a circular recessed glue inlet point 143 at the top of the inner annular groove 140 or the outer annular groove 141, or both, which connects to the branch nozzle 17, and precisely positioning its vertical projection within the common coverage area of ​​the inner / outer annular groove 141, the most direct vertical injection of glue from the branch nozzle 17 to the annular distribution channel is achieved. This avoids unnecessary turning and long-distance flow of the glue within the path plate 14, reducing local pressure and temperature losses. On the other hand, after the glue falls vertically into the annular groove from the glue inlet point 143, it can quickly diffuse in both directions circumferentially, making the pressure build up more quickly and evenly within the annular distribution channel. This lays a solid foundation for subsequent synchronous and uniform vertical filling through the bottom glue injection hole 144, thereby optimizing the synchronization and consistency of filling from the source.

[0030] As a preferred embodiment of this application, Figure 5 and Figure 6 The injection holes 144 on the path plate 14 have a cross-sectional shape that gradually narrows from the injection direction to the discharge direction. On the mating surface of the path plate 14 facing the rotor core 30, a hollow truncated cone 145 is integrally formed for each injection hole 144. When the mold is closed, the lower end of the hollow truncated cone 145 is inserted into and tightly fitted into the gap entrance between the corresponding permanent magnet and the core slot on the rotor core 30.

[0031] This implementation method offers two main advantages: First, the tapered cross-section design of the injection hole 144, which gradually narrows from the injection direction to the outlet direction, creates a natural flow channel convergence area. This not only maintains the flow pressure of the adhesive during filling, preventing pressure drop and unstable filling due to sudden expansion of the flow channel, but also generates a certain compression and acceleration effect on the adhesive through cross-sectional changes, allowing it to be injected into the gap of the magnet 31 in a more uniform and dense state. This helps to remove air and reduce the risk of internal air bubbles and insufficient filling. Second, it achieves precise sealing and alignment. The integrally formed hollow truncated cone 145 forms an interlocking fit with the gap inlet of the rotor core 30. This firstly provides precise positioning and guidance physically, ensuring the alignment of the injection hole 144 with the complex rotor slots. More importantly, this plug-in structure forms a mechanical sealing ring after mold closing, which can effectively prevent the material from overflowing from the gap entrance during high-pressure injection, causing flash or leakage. This ensures that all the material is constrained and accurately injected into the target cavity, thereby improving the molding quality and dimensional consistency of the insulation layer, and eliminating the need for subsequent flash cleaning.

[0032] As a preferred embodiment of this application, see [link to application]. Figure 4 and Figure 7The upper mold assembly also includes an upper mold core 13, which is fixedly disposed above the path plate 14. Its lower surface and the upper surface of the path plate 14 together close the top opening of the flow channel groove. An upper pad plate 12 is fixedly disposed above the upper mold core 13. Each of the branch nozzles 17 passes through the upper pad plate 12 and the upper mold core 13 in sequence, and its outlet is connected to the glue inlet point 143 of the path plate 14. A hollow ejector plate 15 that can move along the mold opening and closing direction is sleeved on the outer periphery of the path plate 14. Under the action of the drive mechanism, the hollow ejector plate 15 can be ejected after the mold is opened and drive the path plate 14 and the upper mold core 13 to open the closed-loop flow channel path. The robot picks up the material target, making the automatic removal process of waste simple and reliable. This transforms the complex operation that traditionally relies on manual cleaning into a standardized and rhythmic action that can be seamlessly integrated into the automated production line, greatly improving production continuity and efficiency.

[0033] As a preferred embodiment of this application, see [link to application]. Figure 8 and Figure 9 The lower mold base 20 includes a central placement disk 21 and clamping blocks 22 symmetrically arranged on both sides of the placement disk 21 that can move radially. Each clamping block 22 has an oblique hole 220. The lower mold base 20 is provided with a clearance hole 200. The upper mold assembly is correspondingly provided with an oblique guide post 150. During the mold closing process, the oblique guide post 150 is inserted into the corresponding oblique hole 220, driving the two clamping blocks 22 to move towards each other, applying radial extrusion force to the rotor core 30 placed on the placement disk 21 to clamp and fix it.

[0034] The linkage mechanism between the inclined guide post 150 and the clamping block 22 achieves self-centering and rigid clamping of the rotor core 30 during mold closing. Its core advantage lies in precisely converting the downward kinetic energy of the upper mold into radial extrusion force by the inclined guide post 150, automatically and firmly clamping and precisely positioning the rotor core 30 as the mold closes. This not only effectively resists the radial expansion force generated by the high pressure of the rubber material during injection molding, preventing micro-movement of the core and ensuring precise alignment between the gap of the magnet 31 and the injection hole 144; but also seamlessly integrates the entire clamping action with the mold closing process, eliminating the need for additional drive devices, thus improving equipment reliability and production cycle time. It is a key guarantee for achieving high-precision, automated assembly.

[0035] The adhesive itself is injected carrying high heat, typically much higher than the initial temperature of the rotor core. When the first batch of adhesive comes into contact with the cold rotor core's 30 slot walls, instantaneous heat exchange occurs. The heat rapidly heats the contacted area of ​​the rotor core, forming a small high-temperature zone. Since the rotor core is a good conductor of heat, even if subsequent batches of adhesive arrive tens of milliseconds later and are injected into adjacent sections, their base temperature is no longer uniform. This temperature gradient, directly caused by the time difference, results in different areas of the adhesive being at different cooling rates and curing starting points from the moment of injection. This asynchronous curing due to temperature differences during the filling stage affects the final internal structure of the cured adhesive layer.

[0036] Due to differences in curing initiation time and speed, the curing process of thermoplastics (such as PPS, PEEK, nylon, and other engineering plastics) is physical cooling and crystallization rather than a chemical reaction. This makes the harmful logic of "temperature difference relay" different from that of thermosetting plastics, but the resulting consequences such as interface failure, structural inhomogeneity, and performance degradation are equally serious.

[0037] When thermoplastic compounds cool from a molten state, the cooling rate directly determines their crystallinity, molecular chain orientation, and internal stress. When the compound in gap A cools at, for example, 10°C, while the compound in adjacent gap B cools at 12°C, their thermal histories differ significantly. Gap B, cooling more slowly, allows for longer molecular chain relaxation and crystallization, resulting in differences in shrinkage rate, final crystallinity, and internal stress level compared to gap A. Each gap filled with compound exerts a shrinkage clamping force on the magnets 31 and the core on both sides during cooling and shrinkage. However, due to differences in the cooling rate and shrinkage amount of the compound in each gap, the magnitude and establishment time of the clamping force also differ. The compound in some gaps has completely cooled and solidified, while the compound in others is still shrinking. This asynchronous shrinkage creates an uneven micro-stress field within the complex V-shaped magnetic circuit. In areas with greater shrinkage stress or those compressed by the shrinkage of adjacent gaps, localized stress concentrations occur within the compound layer or at the interface between the compound layer and the magnets 31 / core. Under the immense alternating electromagnetic force and thermal cycling generated by the high-speed operation of the motor, these stress concentration points are highly susceptible to becoming the origin of microcracks. The bonding strength between the rubber compound and the metal is also affected by the cooling process. Uneven cooling may cause some interfaces to be in a state of residual tensile stress, weakening the bonding force. Ultimately, the overall fixing strength of the rotor is determined by the weakest gap.

[0038] To address the aforementioned issues, as a preferred embodiment of this application, the placement tray 21 of the lower mold base 20 integrates an independent temperature control system. This system is configured to maintain the temperature of the rotor core 30 within a set temperature range that prevents the adhesive from solidifying during the adhesive injection process. After all adhesive is injected, the rotor core 30 and the adhesive within the gaps are simultaneously and uniformly solidified. The entire rotor core 30 is preheated and stabilized at a uniform platform higher than the adhesive's crystallization temperature. This ensures that the adhesive in all gaps remains completely molten and non-crystallized during the filling stage, completely eliminating the initial temperature difference caused by the filling sequence. During the cooling stage: after all the adhesive in all gaps is at the same starting point, a uniform cooling process is initiated. The aim is to ensure that all adhesives begin and complete crystallization and solidification at the closest possible rates.

[0039] This ensures that the adhesive layer within each V-groove has a uniform crystalline structure, consistent shrinkage behavior, and balanced residual stress, resulting in overall uniform high bonding strength and high reliability. This fundamentally solves the performance differentiation problem caused by different thermal histories in sequential filling of thermoplastic materials.

[0040] Furthermore, a sealed vibration chamber 222 is provided inside the clamping block 22, and an impactor 223 that can roll freely is provided inside the vibration chamber 222; the impactor 223 moves and generates impacts in the vibration chamber 222, thereby transmitting the vibration to the rotor core 30.

[0041] The V-shaped magnet 31 has a complex groove structure, especially at the junction of the "large V" and "small V", the bottom of the groove, and the irregular tiny gaps between the magnet 31 and the iron core. When high-viscosity molten adhesive fills these areas, air cannot escape as smoothly as in an open space. Even if the mold is designed with venting grooves, air bubbles hidden deep in the complex cavity are extremely difficult to expel and are eventually encapsulated by the adhesive, forming internal voids or weak bonding areas at the interface. These voids, during motor operation, can become the starting point for insulation breakdown or crack propagation due to stress concentration.

[0042] Furthermore, when thermoplastic melt flows in narrow gaps, its leading edge cools rapidly upon contact with a cooler metal wall, causing a sharp increase in viscosity and forming a so-called stagnant layer. Subsequent compounding requires higher pressure to move the now viscous leading edge, increasing the risk of incomplete filling.

[0043] This application, based on the heating system installed on the placement tray 21, introduces a clamping block 22, an impactor 223, and a vibration chamber 222. Essentially, this injects stress waves into the entire glue injection system and the glue itself. Specifically, see... Figure 11In the inclined cavity design, high-pressure gas is periodically blown into one end of the cavity, driving the balls (impactor 223) to accelerate upwards along the inclined plane, causing them to impact the top of the cavity or a specific impact surface at high speed. At the moment of impact, the momentum of the balls undergoes a sudden change, and their kinetic energy is converted into a high-frequency stress pulse (i.e., a mechanical wave). This pulse is then transmitted through the solid contact surface in the form of an elastic wave to the entire clamping block 22 and the rotor core 30 in close contact with it. Subsequently, the blowing stops and the pressure is released, and the balls roll back to the starting point along the inclined plane under the action of gravity, completing one cycle and storing energy for the next impact. This design can precisely adjust the frequency and intensity of the impact by controlling the frequency and pressure of the blowing, thereby injecting a series of controllable mechanical waves into the rubber compound.

[0044] Mechanical waves are transmitted to the iron core and act on the molten adhesive within the gaps, generating continuous microscopic shear and pressure disturbances. This effectively reduces the apparent viscosity of the adhesive, improves its flow properties, and ensures that the adhesive fully fills the ends of narrow gaps and microscopic grooves. Furthermore, the pressure disturbances disrupt and drive the migration and merging of trapped air bubbles in the adhesive, allowing them to be discharged through the venting system. This significantly reduces or eliminates internal defects such as voids and air bubbles in the cured adhesive layer, resulting in a dense and uniform insulating layer. The vibrations also promote the adhesive to fully fill the microscopic rough structure of the metal surface, achieving a deeper level of mechanical interlocking. The combined effect is a significant increase in the actual bonding strength between the adhesive and the metal interface, and a more uniform adhesive layer performance throughout the rotor, thus ensuring the long-term operational reliability of the motor under high-speed, high-load conditions.

[0045] In a preferred embodiment of this application, the lower mold base 20 is provided with two parallel pressure rails 23, and stepped sliders 221 extend laterally from both sides of the clamping blocks 22. The pressure rails 23 are located on the upper step surface of the stepped sliders 221 and a vertical gap is maintained between them. The lower mold base 20 is also provided with a limiting part 24, which is located on the opposite side of the two clamping blocks 22 and is used to limit the outward movement of the clamping blocks 22.

[0046] The pressure rail 23 covers the stepped slider 221, forming a stable lateral sliding guide. The inclined guide post 150 can smoothly enter the inclined hole 220, thus smoothly and centrally completing the transition from mold opening to clamping, protecting the precision mating surface between the inclined guide post 150 and the inclined hole 220. On the other hand, the limiting parts 24 on both sides strictly limit the maximum outward stroke of the clamping block 22, ensuring that the clamping block 22 can reliably return to the standby position when the mold is opened, and completely preventing the clamping block 22 from accidentally coming out of the guide rail due to inertia or vibration during the mold opening and ejection process. This greatly improves the safety and reliability of the mold during long-term operation and achieves the unity of guiding accuracy and operational safety.

[0047] A method for using a production mold for a new energy synchronous rotor specifically includes the following steps: S1: The upper mold closes and clamps tightly with the rotor core 30 internal support. The rotor core 30, pre-loaded with V-shaped permanent magnets, is precisely positioned at the center of the placement plate 21 on the lower mold base 20 by a robotic arm. Subsequently, the upper mold assembly descends, and its inclined guide post 150 is precisely inserted into the inclined hole 220 of the clamping block 22. As the upper mold continues to descend, the inclined guide post 150 and the inclined surface of the inclined hole 220 generate a radial force, smoothly and synchronously driving the two clamping blocks 22 along the pressure rail 23 and the stepped slider 221, moving radially towards each other, ultimately firmly radially supporting and positioning the rotor core 30 at the center of the placement plate 21 from its inner hole. This step is fully automated, eliminating errors and inconsistencies from manual clamping and ensuring absolute zero displacement of the rotor during subsequent high-pressure glue injection, laying a rigid foundation for obtaining a uniform glue layer and excellent dynamic balance.

[0048] S2: System preheating and temperature field establishment After the mold closes, the hot runner system (integrated in the manifold 11) and the main nozzle 16 and branch nozzles 17 are immediately energized and heated, rapidly reaching and stabilizing at the optimal melt processing temperature of the rubber compound (such as high-performance thermoplastic engineering plastics). Simultaneously, the temperature control system integrated within the placement tray 21 is activated, preheating the placement tray 21 and the rotor core 30 in close contact with it via the built-in heating element 111, and precisely maintaining it at a set value higher than the crystallization temperature of the rubber compound. This step aims to establish a uniform and controllable initial temperature field, ensuring optimal fluidity of the rubber compound throughout the conveying path and achieving thermal equilibrium for the rotor core 30, thus creating conditions for subsequent synchronous filling and synchronous cooling and curing.

[0049] S3: Multi-channel synchronous precision dispensing The external injection molding machine starts, and high-pressure molten rubber is injected into the mold through the main nozzle 16. The rubber enters the manifold 11 and is evenly distributed to each branch nozzle 17 through multiple radially distributed manifolds 110. Subsequently, the rubber exits from each branch nozzle 17 and is injected into the closed-loop flow path formed by the inner ring groove 140, radial connecting groove 142, and outer ring groove 141 through multiple injection points 143 on the top of the inner and outer ring grooves 141 on the path plate 14. While filling this annular flow path, the rubber passes through the densely distributed injection holes 144 at the bottom of the flow path and is guided and sealed by the hollow conical truncated cone 145, directly injected into the narrow gap between each permanent magnet and the iron core groove from multiple points preset directly above the gap of each magnet 31.

[0050] S4: Vibration-assisted venting and fusion During or immediately after glue injection, the vibration system of the impactor 223 built into the clamping block 22 is activated. The mechanical vibration waves generated by the impact are transmitted to the molten glue in all gaps through the clamping block 22 and the rotor core 30. This vibration has two core effects: first, through local pressure fluctuations and shear thinning effects, it disturbs and drives the tiny air bubbles entrained in the glue to migrate, merge, and eventually be discharged towards the exhaust path, significantly reducing internal voids; second, it breaks the stagnant layer formed at the glue flow front due to contact with the cold wall surface, avoiding the formation of weak bonding cold joints, thereby improving the overall density and continuity of the glue layer.

[0051] S5: Programmed pressure holding and synchronous curing After the adhesive is injected, a pressure holding stage is initiated to compensate for the cooling and shrinkage of the adhesive. Simultaneously, the temperature control system of the placement tray 21 executes a preset heat-holding followed by cooling procedure: First, the system maintains a high temperature, allowing the filled adhesive sufficient time for molecular chain relaxation and flow fusion under pressure, ensuring complete filling; once the adhesive in all gaps is uniform in state, the system initiates a uniform cooling procedure (such as introducing a cooling medium), causing the entire rotor core 30 and its internal adhesive to cool, crystallize, and solidify at a controlled and consistent rate. This step actively manages the curing sequence of the adhesive, eliminating thermal history differences caused by different filling sequences, ensuring synchronous curing of the adhesive layer in all gaps, thereby achieving uniform crystallinity, shrinkage rate, and internal stress distribution, and avoiding the risk of localized weakness or cracking due to uneven curing.

[0052] S6: Mold opening, ejection, and finished product removal After the adhesive has fully cured, all heating systems are shut off. The upper mold assembly moves upward, and the inclined guide post 150 is pulled out, driving the clamping block 22 to radially reset and release the rotor. Subsequently, the hollow ejector plate 15 moves, first lifting the path plate 14 as a whole, separating it from the upper mold core 13, thereby removing the material 4 cured in the closed-loop flow path (inner ring groove 140, outer ring groove 141, radial connecting groove 142) as a complete annular structure. This design greatly simplifies the waste removal process and improves efficiency. Finally, the robot safely removes the finished rotor, which has been fixed with adhesive, from the placement tray 21, ending a complete production cycle, and the mold is ready for the next cycle.

[0053] For any parts not mentioned in this invention, existing technologies can be used or referenced.

[0054] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various variations or substitutions within the technical scope disclosed in the present invention, and these should all be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A production mold for a new energy synchronous rotor, comprising an upper mold assembly and a lower mold assembly, characterized in that, The upper mold assembly, from top to bottom, includes: The main nozzle, with its tip used to connect to the nozzle of an external injection molding machine to receive molten rubber; The flow divider plate has multiple flow channels radially distributed around the main nozzle outlet, with the inlet of each flow channel connected to the outlet of the main nozzle. Multiple branch nozzles have their inlets connected to the outlets of their respective flow channels. A path plate has interconnected inner and outer annular grooves and multiple radial connecting grooves, forming a closed-loop flow path. The outlets of the multiple branch nozzles are connected to multiple glue inlet points on the closed-loop flow path. Multiple glue injection holes are evenly distributed at the bottom of the inner and outer annular grooves and each radial connecting groove. The lower mold assembly includes a lower mold base for placing the rotor core. When the mold is closed, all the injection holes at the bottom of the path plate are aligned with the gaps between the permanent magnets on the rotor core and the slot walls.

2. The production mold for new energy synchronous rotors according to claim 1, characterized in that, The top of the inner annular groove of the path plate is provided with a plurality of circular recesses evenly spaced along the circumference. These circular recesses constitute the glue inlet points for the branch nozzle outlets. The vertical projection of the glue inlet points is located in the area covered by the inner annular groove and / or the outer annular groove.

3. The production mold for new energy synchronous rotors according to claim 1, characterized in that, The injection holes on the path plate have a cross-sectional shape that gradually narrows from the injection direction to the discharge direction. On the mating surface of the path plate facing the rotor core, a hollow truncated cone is integrally formed for each injection hole. When the mold is closed, the lower end of the hollow truncated cone is inserted into and tightly fitted into the gap entrance between the corresponding permanent magnet and the core slot on the rotor core.

4. The production mold for new energy synchronous rotors according to claim 1, characterized in that, The manifold integrates a hot runner system, which includes heating elements embedded in the upper and lower surfaces of the manifold. The main nozzle, the manifold channels in the manifold, and the branch nozzles are all located within the heating temperature zone of the hot runner system, so that the flowing adhesive remains in a molten state.

5. The production mold for new energy synchronous rotors according to claim 1, characterized in that, The upper mold assembly also includes an upper mold core, which is fixedly disposed above the path plate, and its lower surface and the upper surface of the path plate together close the top opening of the flow channel groove; an upper pad plate, which is fixedly disposed above the upper mold core; each of the branch nozzles passes through the upper pad plate and the upper mold core in sequence, and its outlet is connected to the glue injection point of the path plate; a hollow ejector plate that can move along the mold opening and closing direction is sleeved on the outer periphery of the path plate; under the action of the driving mechanism, the hollow ejector plate can be ejected after the mold is opened and drive the path plate to separate from the upper mold core, so as to open the closed-loop flow channel path.

6. The production mold for new energy synchronous rotors according to claim 1, characterized in that, The lower mold base includes a central placement plate and clamping blocks symmetrically arranged on both sides of the placement plate that can move radially. Each clamping block has an oblique hole, and the upper mold assembly is correspondingly provided with an oblique guide post. During the mold closing process, the oblique guide post is inserted into the corresponding oblique hole, driving the two clamping blocks to move towards each other, applying radial extrusion force to the rotor core placed on the placement plate to clamp and fix it.

7. The production mold for a new energy synchronous rotor according to claim 6, characterized in that, The lower mold base has an integrated independent temperature control system inside its placement tray. The temperature control system is configured to maintain the temperature of the rotor core within a set temperature range that prevents the adhesive from curing during the injection process. After all the adhesive is injected, the adhesive in the rotor core and the gap is cured synchronously and uniformly.

8. The production mold for a new energy synchronous rotor according to claim 6, characterized in that, The clamping block has a sealed vibration chamber inside, and an impactor that can roll freely is provided in the vibration chamber; the impactor moves in the vibration chamber and generates impact, thereby transmitting the vibration to the rotor core.

9. The production mold for a new energy synchronous rotor according to claim 6, characterized in that, The lower mold base is provided with two parallel pressure rails, and stepped sliders extend laterally from both sides of the clamping block. The pressure rails are located above the upper step surface of the stepped sliders and maintain a vertical gap with the upper step surface. The lower mold base is also provided with a limiting part, which is located on the opposite side of the two clamping blocks and is used to limit the outward movement of the clamping blocks.

10. A method of using a production mold for a new energy synchronous rotor as described in any one of claims 1-9, characterized in that, Includes the following steps: S1: The rotor core, which has been initially loaded with permanent magnets, is placed on the placement plate of the lower mold base by the robotic arm. The upper mold assembly moves downward, and the inclined guide post on it is inserted into the inclined hole of the clamping block. The clamping block is driven to move along the pressure rail and the step slider guide to radially support and fix the rotor core to the center of the placement plate. S2: The hot runner system is powered on and heated to the melting temperature of the rubber compound. The temperature control system of the placement tray is activated to preheat the rotor core and maintain it at the set temperature. S3: The external injection molding machine injects glue through the main nozzle. The molten glue is distributed to each branch nozzle through the distribution channel. It is injected into the inner ring groove, radial connecting groove and outer ring groove of the injection point through the injection point. It is injected into each gap through all injection holes through the hollow cone. S4: The clamping block's built-in impactor strikes the cavity wall, generating vibration that is transmitted to the rotor, aiding in exhaust and filling; S5: After the glue is injected, pressure is maintained, and the temperature control system of the tray executes the preset program. First, heat is maintained to allow the glue to flow and fuse fully, and then cooling is started to allow the glue in all gaps to cure synchronously and evenly. S6: After curing, all heating systems are turned off, the upper mold moves upward, the inclined guide post drives the clamping block to release the rotor, the hollow ejector plate moves, lifts the path plate to separate it from the upper mold core, opens the closed loop flow path to remove the material, and the robot arm removes the finished rotor.

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