Device for insulating coating of soft magnetic powder

Abstract

The utility model discloses a kind of soft magnetic powder insulation coating devices, including stirring bucket, stirring subassembly, mould temperature controller, temperature sensor and control unit;Temperature sensor is set to stirring bucket for detecting the real-time temperature of material;Heat exchange pipeline is equipped in the interlayer space between outer barrel and inner barrel of stirring bucket, and heat exchange pipeline and mould temperature controller form closed circulation loop, to heat or cool stirring bucket;Stirring subassembly includes stirring motor, stirring shaft, upper layer stirring paddle and lower layer stirring paddle, for the material in stirring bucket is stirred.The utility model integrates double-layer stirring structure and closed-loop temperature control mechanism, and cooperatively solves the problems of agglomeration, mixing dead angle and temperature fluctuation in the coating process of superfine magnetic powder;The cooperation of mould temperature controller and temperature sensor realizes real-time monitoring and dynamic adjustment of material temperature, and ensures the stability of temperature field in process.

Description

Technical Field

[0001] This utility model relates to the technical field of soft magnetic material processing equipment, and in particular to a device for insulating and coating soft magnetic powder. Background Technology

[0002] Soft magnetic powder cores, as a key soft magnetic composite material, are widely used in modern electronic and power fields such as high-frequency inductors, new energy vehicle reactors, photovoltaic inverters, and aerospace power management systems due to their excellent properties, including low eddy current loss and high DC bias characteristics. Their core performance largely depends on the quality of the insulating coating layer on the surface of the magnetic powder particles, namely the uniformity, integrity, and density of the coating layer. However, current production processes, especially when handling ultrafine magnetic powders with an average particle size of less than 20 μm, face significant technological challenges.

[0003] Current methods for insulating powder surfaces largely rely on single-layer stirring devices or conventional agitators. When processing ultrafine powders, these devices generally suffer from a limited flow field and insufficient three-dimensional mixing capacity, resulting in numerous mixing dead zones within the container. More significantly, their shear force is insufficient to effectively break up the tightly aggregated particles formed by van der Waals forces and other factors, causing some particles to fail to be effectively coated by the insulating resin. This creates localized conductive pathways, ultimately severely degrading the magnetic properties of the finished product and leading to a significant increase in eddy current losses.

[0004] Meanwhile, the resin curing or solvent evaporation processes involved in the insulation coating are extremely sensitive to temperature, requiring equipment with rapid and precise temperature control capabilities. Traditional mixing equipment typically employs simple jacket heating or cooling methods, which suffer from slow heating and cooling rates, poor temperature control accuracy, and significant temperature fluctuations, making it difficult to meet the stringent requirements of the process window. Uneven and uncontrolled temperature can easily lead to defects such as resin pre-curing, solvent residue, or coating layer cracking.

[0005] Although some improvements have emerged in the industry, such as adjustable-speed mixers or jacketed mixing tanks, which have improved mixing efficiency or temperature control to some extent, these localized optimization solutions have failed to fundamentally solve the synergistic challenges of the two key process steps: "efficient, dead-angle-free mixing" and "high-precision, rapid-response temperature control." Uneven mixing and inaccurate temperature control are mutually restrictive, becoming a bottleneck that limits the consistency and further performance improvement of high-performance metal soft magnetic powder core products.

[0006] Therefore, for the manufacturing of high-performance metal soft magnetic powder cores, the industry urgently needs to develop an integrated professional equipment that can comprehensively solve the problems of ultrafine powder agglomeration, three-dimensional uniform mixing and precise control of process temperature, so as to fundamentally improve the insulation coating quality and meet the increasingly stringent requirements of high-end application fields for material performance. Utility Model Content

[0007] In view of the problems raised in the background art, the purpose of this utility model is to provide a device for soft magnetic powder insulation coating, which improves the uniformity and efficiency of insulation coating by optimizing the stirring flow field and temperature management.

[0008] To achieve this objective, the present invention adopts the following technical solution: A device for soft magnetic powder insulation coating includes a mixing tank, a mixing assembly, a mold temperature controller, a temperature sensor, and a control unit, wherein the control unit is communicatively connected to the mixing assembly, the mold temperature controller, and the temperature sensor. The temperature sensor is installed inside the mixing tank and is used to detect the real-time temperature of the material. The mixing tank includes an outer tank and an inner tank, with a sandwich space formed between the outer tank and the inner tank. A heat exchange pipe is provided in the sandwich space. The inlet and outlet of the heat exchange pipe are connected to the mold temperature controller through pipelines to form a closed loop. The mold temperature controller is used to regulate the temperature of the internal medium flowing through the heat exchange pipe, thereby heating or cooling the mixing tank. The stirring assembly includes a stirring motor, a stirring shaft, an upper stirring paddle, and a lower stirring paddle. The stirring shaft is connected to the output end of the stirring motor, and the upper and lower stirring paddles are respectively installed on the stirring shaft. The stirring assembly is used to stir the materials in the stirring tank.

[0009] Preferably, the mold temperature controller includes a heating module, a cooling module, and a circulating pump; The heat exchange pipeline includes a hot circulation pipeline and a cold circulation pipeline, and the hot circulation pipeline and the cold circulation pipeline are independent of each other; The inlet and outlet of the heat circulation pipe are connected to the heating module through the first pipeline to form a heat circulation loop. The circulation pump is used to drive the internal medium of the heating module to circulate in the heat circulation loop. The inlet and outlet of the cold circulation pipe are connected to the cooling module through a second pipe to form a cold circulation loop. The circulation pump is used to drive the internal medium of the cooling module to circulate in the cold circulation loop.

[0010] Preferably, both the hot circulation pipe and the cold circulation pipe are spirally wound in the interlayer space, and the hot circulation pipe and the cold circulation pipe are alternately arranged in sequence along the height direction of the mixing tank.

[0011] Preferably, the upper agitator is positioned above the lower agitator, the upper agitator has a diameter of D1, and the lower agitator has a diameter of D2, wherein 1 ≤ D1 / D2 ≤ 1.2.

[0012] Preferably, the upper and lower stirring paddles have the same structure, including a stirring hub and a plurality of stirring blades. The stirring hub is sleeved on the stirring shaft, and the plurality of stirring blades are spaced apart on the outer edge of the stirring hub. The stirring blades are inclined in the vertical direction. The upper impeller is used to generate an axial hydrodynamic field, and the lower impeller is used to generate a radial hydrodynamic field.

[0013] Preferably, the stirring blade includes a connecting end, a lower edge of the blade, an upper edge of the blade, and an outer edge of the blade; The connecting end is inclined and fixed to the outer edge of the stirring wheel hub. One end of the lower edge of the blade is connected to the lower end of the connecting end, one end of the upper edge of the blade is connected to the upper end of the connecting end, the other end of the lower edge of the blade is connected to the lower end of the outer edge of the blade, and the other end of the upper edge of the blade is connected to the upper end of the outer edge of the blade.

[0014] Preferably, the angle between the stirring blades of the upper stirring paddle and the horizontal plane is in the range of 30° to 45°.

[0015] Preferably, the angle between the stirring blades of the lower stirring paddle and the horizontal plane is in the range of 40° to 55°.

[0016] Preferably, it further includes a lifting assembly, and the control unit is in continuous communication with the lifting assembly; The stirring motor is installed on the drive end of the lifting assembly, which is used to control the stirring assembly to rise or fall.

[0017] Preferably, the lifting mechanism includes a lifting motor, a lead screw, a nut, and a connecting component; The lifting motor is located outside the mixing tank, the lead screw extends vertically, the output shaft of the lifting motor is driven to one end of the lead screw via a coupling, and the nut is sleeved on the lead screw in a helical transmission manner; One end of the connector is connected to the nut, and the other end of the connector is installed and connected to the stirring motor.

[0018] Compared with the prior art, one of the above technical solutions has the following beneficial effects: 1. By designing the stirring component to work synergistically with the upper and lower layers of stirring paddles, the problems of magnetic powder agglomeration and stirring dead zones are solved, making the insulation coating layer more dense and uniform, and significantly reducing eddy current loss.

[0019] 2. By connecting the mixing tank to the mold temperature controller and combining it with the PID control algorithm, high-precision temperature control is achieved, and the heating and cooling speed is fast, perfectly matching the curing process requirements of insulating resin.

[0020] 3. The strong mixing effect and precise temperature control shorten the magnetic powder coating time from 3-6 hours in traditional equipment to 1-2 hours; the output rate is increased from less than 90% in traditional equipment to more than 95%.

[0021] 4. By adjusting the rotation speed and precisely setting the temperature curve, it can flexibly adapt to the process requirements of different magnetic powder materials and insulation formulas. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of one embodiment of the present invention; Figure 2 This is a schematic diagram of another embodiment of the present invention; Figure 3 This is a schematic diagram of the stirring blade of this utility model.

[0023] The components include: a mixing tank 1, an outer tank 11, an inner tank 12, a sandwich space 13, a heat exchange pipe 14, a hot circulation pipe 141, a cold circulation pipe 142, a mixing assembly 2, a mixing motor 21, a mixing shaft 22, an upper mixing blade 23, a lower mixing blade 24, a mixing hub 201, a mixing blade 202, a connecting end 2021, a lower edge of the blade 2022, an upper edge of the blade 2023, an outer edge of the blade 2024, a mold temperature controller 3, a heating module 31, a first pipe 310, a second pipe 320, a cooling module 32, a circulation pump 33, a lifting assembly 4, a lifting motor 41, a lead screw 42, a nut 43, and a connector 44. Detailed Implementation

[0024] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0025] In the description of this utility model, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0026] Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first," "second," and "third" may explicitly or implicitly include one or more of that feature.

[0027] It should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0028] The following is in conjunction with the appendix Figures 1 to 3 The technical solution of this utility model will be further illustrated through specific implementation methods.

[0029] A device for insulating coating with soft magnetic powder includes a mixing tank 1, a mixing assembly 2, a mold temperature controller 3, a temperature sensor, and a control unit. The control unit is communicatively connected to the mixing assembly 2, the mold temperature controller 3, and the temperature sensor. The temperature sensor is installed inside the mixing tank 1 and is used to detect the real-time temperature of the material. The mixing tank 1 includes an outer tank 11 and an inner tank 12, with a sandwich space 13 formed between the outer tank 11 and the inner tank 12. A heat exchange pipe 14 is provided in the sandwich space 13. The inlet and outlet of the heat exchange pipe 14 are respectively connected to the mold temperature controller 3 through pipelines to form a closed loop. The mold temperature controller 3 is used to regulate the temperature of the internal medium flowing through the heat exchange pipe 14, thereby heating or cooling the mixing tank 1. The stirring assembly 2 includes a stirring motor 21, a stirring shaft 22, an upper stirring paddle 23, and a lower stirring paddle 24. The stirring shaft 22 is connected to the output end of the stirring motor 21, and the upper stirring paddle 23 and the lower stirring paddle 24 are respectively installed on the stirring shaft 22. The stirring assembly 2 is used to stir the material in the stirring tank 1.

[0030] This invention proposes a device for insulating coating of soft magnetic powder. Through the coordinated operation of a mixing tank 1, a mixing assembly 2, a mold temperature controller 3, a temperature sensor, and a control unit, it solves the problems of uneven mixing, dead zones, and inaccurate temperature control caused by agglomeration of ultrafine magnetic powder during the insulating coating process. The mixing tank 1 consists of an outer tank 11 and an inner tank 12, forming a sandwich space 13. A heat exchange pipe 14 is installed within the sandwich space 13, forming a closed loop with the mold temperature controller 3 to achieve heating or cooling of the mixing tank 1. Furthermore, a temperature sensor is installed inside the mixing tank 1 to detect the real-time temperature of the material and transmit the data to the control unit. The control unit dynamically adjusts the operating state of the mold temperature controller 3 based on the received temperature signal to ensure that the temperature inside the mixing tank 1 remains within the required process range.

[0031] The mixing assembly 2 includes a mixing motor 21, a mixing shaft 22, an upper mixing blade 23, and a lower mixing blade 24. The mixing shaft 22 is connected to the output end of the mixing motor 21, and the upper mixing blade 23 and the lower mixing blade 24 are respectively installed at different positions on the mixing shaft 22. Specifically, the upper mixing blade 23 rapidly pumps the material from the upper part of the tank to the bottom, forming a large-scale macroscopic circulation. The lower mixing blade 24 can effectively disperse the magnetic powder agglomerates gathered at the bottom of the tank. Thus, the synergistic effect of the two mixing blades forms a composite flow field from strong axial circulation to high shear radial flow within the tank, significantly reducing mixing dead zones and improving the uniformity of the material.

[0032] The mold temperature controller 3 rapidly heats or cools the mixing tank 1 by adjusting the temperature of the internal medium flowing through the heat exchange pipe 14. Specifically, the internal medium of the mold temperature controller 3 can be water, oil, or other heat transfer media, and temperature regulation is achieved through heating or cooling equipment. Furthermore, the mold temperature controller 3 can be controlled manually or automatically to meet different process requirements. The heat exchange pipe 14 is rationally arranged within the interlayer space 13, enabling efficient heat transfer, reducing temperature gradients, and maintaining a stable temperature environment. After receiving real-time feedback signals from the temperature sensor, the control unit synchronously adjusts the operating status of the mixing assembly 2 and the mold temperature controller 3 to ensure dynamic matching between the mixing process and temperature control. For example, when the material temperature deviates from the set value, the control unit can quickly adjust the heating or cooling power of the mold temperature controller 3, while simultaneously driving the mixing assembly 2 to operate at an appropriate speed, thereby ensuring that the material is fully mixed under uniform temperature conditions.

[0033] This invention integrates a double-layer stirring structure with a closed-loop temperature control mechanism to collaboratively solve the problems of agglomeration, mixing dead zones, and temperature fluctuations during the coating process of ultrafine magnetic powder. The double-layer design of the stirring component 2 expands the stirring coverage area and reduces mixing dead zones, while the functional division of different layers of stirring paddles enables the generation of a multi-directional flow field. The mold temperature controller 3, in conjunction with a temperature sensor, enables real-time monitoring and dynamic adjustment of the material temperature, ensuring the stability of the temperature field during the process. Therefore, this device can accurately control the temperature while efficiently mixing, providing reliable technical support for the uniform coating of ultrafine magnetic powder.

[0034] Furthermore, the mold temperature controller 3 includes a heating module 31, a cooling module 32, and a circulating pump 33; The heat exchange pipe 14 includes a hot circulation pipe 141 and a cold circulation pipe 142, and the hot circulation pipe 141 and the cold circulation pipe 142 are independent of each other; The inlet and outlet of the heat circulation pipe 141 are connected to the heating module 31 through the first pipe 310 to form a heat circulation loop. The circulation pump 33 is used to drive the internal medium of the heating module 31 to circulate in the heat circulation loop. The inlet and outlet of the cold circulation pipe 142 are connected to the cooling module 32 through the second pipe 320 to form a cold circulation loop. The circulation pump 33 is used to drive the internal medium of the cooling module 32 to circulate in the cold circulation loop.

[0035] Specifically, the mold temperature controller 3 is a device that implements temperature regulation, and it can be implemented using an integrated or separate design. The heating module 31 provides a heat source, which can achieve heat output through heating with heat transfer oil. The cooling module 32 provides a cold source, which achieves cooling effect through cold water circulation. The circulating pump 33 is a power device used to drive the flow of the medium, and it can be a centrifugal pump, the purpose of which is to ensure the stable flow of the medium in the circulation loop.

[0036] The heat exchange pipe 14 is a pipe structure installed within the interlayer space 13 of the mixing tank, and it can be made of metal, plastic, or composite materials. The independent arrangement of the hot circulation pipe 141 and the cold circulation pipe 142 aims to avoid mutual interference between the hot and cold media, thereby improving the accuracy of temperature control. The first pipe 310 and the second pipe 320 are used to connect the corresponding circulation loops, and they can be sealed through flange connections, threaded connections, or welding.

[0037] Specifically, by constructing a dual-mode independent temperature control system, the coordinated operation of heating and cooling functions is achieved. The heating module 31 serves as the heat source, and the cooling module 32 as the cold source. Both are connected to the hot circulation pipe 141 and the cold circulation pipe 142 respectively via independent circulation loops. The circulation pump 33 plays a synergistic driving role in the dual loops, not only maintaining stable flow of the medium in each circulation loop but also significantly shortening the heat exchange time window by precisely matching flow rate and temperature requirements. This separate architecture effectively avoids the thermal inertia interference during mode switching in traditional single systems, ensuring that temperature regulation commands can be instantly translated into physical actions.

[0038] Furthermore, the hot circulation pipe 141 forms a dedicated hot circulation loop with the heating module 31 via the first pipe 310. This path is optimized for efficient heat transfer, allowing heat to be injected directionally and without loss into the jacket space 13 of the mixing tank, achieving linear and controllable heating. The cold circulation pipe 142 forms a dedicated cold circulation loop with the cooling module 32 via the second pipe 320. This path is designed for rapid heat dissipation, ensuring that the cooling capacity can instantly cover the target area when cooling demand is triggered, eliminating the lag inherent in traditional cooling methods that rely on ambient heat dissipation. This design, combined with a PID control algorithm, achieves a temperature control accuracy of ±1℃, with rapid heating and cooling rates, perfectly matching the curing process requirements of the insulating resin.

[0039] Furthermore, both the hot circulation pipe 141 and the cold circulation pipe 142 are spirally wound in the interlayer space 13, and the hot circulation pipe 141 and the cold circulation pipe 142 are alternately arranged in the height direction of the mixing tank 1.

[0040] A spiral shape refers to a geometric configuration where pipes are arranged along the outer wall of the mixing tank 1 (inner tank 12) in a continuous spiral trajectory. This configuration can be achieved through machining or forming processes. In practical applications, the spiral design of the hot circulation pipe 141 and the cold circulation pipe 142 significantly increases the contact area with the wall of the mixing tank 1, thereby improving heat exchange efficiency. The purpose of the spiral winding arrangement is to eliminate localized heat transfer blind spots that may result from traditional straight-line arrangements, providing the mixing tank 1 with more efficient heating or cooling capabilities.

[0041] Specifically, the alternating arrangement of the hot circulation pipe 141 and the cold circulation pipe 142 along the height of the mixing tank 1 allows the heating and cooling effects to be interconnected in the vertical dimension. This layout not only effectively avoids temperature stratification caused by height gradients but also ensures that materials in different areas can respond synchronously to temperature regulation during the mixing process. Simultaneously, the spiral winding design ensures good continuity of the medium's flow path within the pipes, further enhancing the heat exchange effect. Based on this structure, a dynamically balanced temperature field can be maintained inside the entire mixing tank 1, thereby solving the problem of coating quality defects caused by uneven temperature.

[0042] Furthermore, the upper stirring paddle 23 is disposed above the lower stirring paddle 24, the diameter of the upper stirring paddle 23 is D1, and the diameter of the lower stirring paddle 24 is D2, wherein 1≤D1 / D2≤1.2.

[0043] Specifically, the upper impeller 23 refers to the agitator located at a higher position in the agitation assembly 2, and its purpose is to provide axial material conveying capability. The lower impeller 24 refers to the agitator located at a lower position in the agitation assembly 2, and it can be made of the same material as the upper impeller, with the purpose of dominating radial diffusion. The diameter ratio of the upper impeller 23 to the lower impeller 24, 1≤D1 / D2≤1.2, is set to ensure a balance in flow field intensity and coverage between the upper and lower impellers.

[0044] In detail, a basic three-dimensional mixing framework is constructed by placing the upper agitator 23 above the lower agitator 24. The diameter D1 of the upper agitator 23 is slightly larger than or equal to the diameter D2 of the lower agitator 24, with the difference strictly controlled within 20%. This design ensures that the upper agitator 23 can provide moderate axial thrust, efficiently pushing the material to the lower region. This structural arrangement avoids situations where the upper flow field is too weak due to an excessively small diameter, making it unable to overcome the resistance to agglomeration of ultrafine powders, or where the flow field is turbulent and energy is wasted due to an excessively large diameter. At the same time, this ratio range is specifically designed for the processing requirements of ultrafine magnetic powders, so that the slightly larger diameter of the upper layer enhances the continuity and uniformity of the downward conveying of materials, complementing the radial action of the lower agitator 24 and effectively eliminating mixing dead zones at the bottom and edges of the container. In addition, the shear force generated by this scheme is just right, which can break up magnetic powder agglomerates without damaging the particle structure, thereby ensuring that the insulating resin forms a uniform and complete coating layer on the surface of each magnetic powder particle.

[0045] Furthermore, the upper stirring paddle 23 and the lower stirring paddle 24 have the same structure, including a stirring hub 201 and a plurality of stirring blades 202. The stirring hub 201 is sleeved on the stirring shaft 22, and the plurality of stirring blades 202 are spaced apart on the outer edge of the stirring hub 201. The stirring blades 202 are inclined in the vertical direction. The upper stirring blade 23 is used to generate an axial hydrodynamic field, and the lower stirring blade 24 is used to generate a radial hydrodynamic field.

[0046] By unifying the structural design of the upper impeller 23 and the lower impeller 24, the problem of insufficient flow field coordination during the mixing of ultrafine magnetic powder is solved. The impeller hub 201 is fitted onto the impeller shaft 22, ensuring efficient transmission of rotational power and maintaining structural stability under high-speed operation. Several impeller blades 202 are spaced apart on the outer edge of the impeller hub 201. Based on the principle of uniform circumferential distribution, this avoids uneven local stirring intensity and provides a basis for forming a continuous and uniform flow field. The design of the impeller blades 202 being inclined in the vertical direction is used to generate fluid shear forces in the vertical (axial) and horizontal (radial) directions during rotation.

[0047] Specifically, when the stirring shaft 22 drives the stirring hub 201 to rotate, the inclined stirring blades 202 generate vertical and horizontal components of force in the direction of rotation, pushing the fluid to form a hydrodynamic field. A continuous pressure gradient is formed between adjacent stirring blades 202, causing powder agglomerates outside the circumference of the stirring paddle to be drawn into the stirring area. In addition, by having the upper stirring paddle 23 guide the axial flow with a smaller tilt angle, the overall circulation of the material is promoted; while the lower stirring paddle 24 enhances the radial shear force with a larger tilt angle, effectively breaking up agglomerates formed by van der Waals forces. This design not only eliminates mixing dead zones but also significantly improves three-dimensional mixing efficiency, thereby achieving a more uniform insulating resin coating effect when processing ultrafine magnetic powder.

[0048] Furthermore, the stirring blade 202 includes a connecting end 2021, a lower edge of the blade 2022, an upper edge of the blade 2023, and an outer edge of the blade 2024; The connecting end 2021 is inclinedly fixed to the outer edge of the stirring hub 201. One end of the lower edge 2022 of the blade is connected to the lower end of the connecting end 2021. One end of the upper edge 2023 of the blade is connected to the upper end of the connecting end 2021. The other end of the lower edge 2022 of the blade is connected to the lower end of the outer edge 2024 of the blade. The other end of the upper edge 2023 of the blade is connected to the upper end of the outer edge 2024 of the blade.

[0049] The connecting end 2021 is a key structure used to fix the stirring blade 202 to the stirring hub 201. It can be achieved by welding, bolting, or integral molding. The inclined fixing design ensures that the stirring blade 202 maintains a preset angle during high-speed rotation, avoiding angular deviation due to material resistance, thereby maintaining the accuracy of the flow field direction. The lower edge 2022 and upper edge 2023 of the blade refer to the upper and lower boundary portions of the stirring blade 202, respectively. Their main function is to strengthen the connection between the stirring blade 202 and the stirring hub 201, and to evenly distribute the force, reducing stress concentration. The outer edge 2024 of the blade is the outer contour boundary of the stirring blade. Its design purpose is to expand the effective shearing area coverage and enhance the tearing effect on ultrafine magnetic powder agglomerates.

[0050] In detail, the inclined fixing method of the connecting end 2021 ensures that the stirring blade 202 is installed at a stable angle on the stirring hub 201, laying the foundation for the subsequent generation of axial or radial flow fields. The lower edge 2022 and the upper edge 2023 of the blade are connected to the upper and lower ends of the connecting end 2021, respectively. This segmented design makes the blade form a continuous and rigid curved surface structure, which can resist the deformation caused by material resistance during high-speed rotation and avoid weakening the shearing effect due to loose structure. At the same time, the connection between the lower edge 2022 and the lower end of the outer edge 2024 of the blade, and the connection between the upper edge 2023 and the upper end of the outer edge 2024 of the blade, together construct a smooth flow path, reduce mixing dead zones, and improve the uniformity and integrity of the insulation coating.

[0051] Furthermore, the angle between the stirring blade 202 of the upper stirring paddle 23 and the horizontal plane is in the range of 30°~45°.

[0052] When the stirring blades 202 are set at an angle of 30° to 45°, the fluid is guided by the stirring blades 202 during rotation, resulting in axial flow mainly along the stirring shaft 22. This axial flow efficiently pushes the surface material to the bottom while lifting the bottom material to the upper area, thus achieving thorough circulation and mixing in the height direction of the mixing tank 1. Furthermore, this angle range provides moderate shear force, gradually breaking up agglomerates formed by van der Waals forces, avoiding powder damage caused by severe impacts, and ensuring that the insulating resin adheres uniformly to the surface of each magnetic powder particle.

[0053] Furthermore, the angle between the stirring blade 202 of the lower stirring paddle 24 and the horizontal plane ranges from 40° to 55°.

[0054] By limiting the angle between the stirring blades 202 of the lower stirring paddle 24 and the horizontal plane to between 40° and 55°, the stirring flow field structure was specifically optimized. When the stirring blades 202 rotate, their tilt angle makes the force more inclined to be distributed horizontally and radially, rather than axially or in random directions, thus ensuring the dominance of radial flow. This flow field mode not only enhances material circulation in the bottom region of the mixing tank 1, but also significantly reduces low-velocity dead zones and improves the uniform dispersion capability in three-dimensional space. In addition, the selection of this angle range avoids the problem of axial flow dominance caused by too small an angle, as well as the turbulence caused by too large an angle, thereby achieving efficient and stable shear force transmission.

[0055] Furthermore, it also includes a lifting assembly 4, and the control unit is in continuous communication with the lifting assembly 4; The stirring motor 21 is installed on the drive end of the lifting assembly 4, and the lifting assembly 4 is used to control the stirring assembly 2 to rise or fall.

[0056] The integrated lifting assembly 4 enables dynamic vertical adjustment of the stirring assembly 2. The stirring motor 21 is directly mounted on the drive end of the lifting assembly 4. This structural design ensures the stability and synchronization of the stirring assembly 2 during lifting, avoiding vibration or displacement caused by height changes. The specific operating logic of the lifting assembly 4 is as follows: During the loading stage, the stirring assembly 2 is raised to unblock the loading channel, reducing the flying of ultrafine powder and operational obstacles; during the stirring stage, the stirring assembly 2 automatically lowers to a suitable depth according to the material state, thereby enhancing shear force distribution and effectively breaking up agglomerates formed by van der Waals forces. Furthermore, the control unit precisely triggers the lifting action based on preset process parameters or real-time feedback information, such as automatically lowering the stirring assembly 2 before stirring starts to fully immerse it in the material, and raising it at the end for easy cleaning and maintenance. This height-adjustable design significantly improves the continuity and uniformity of the stirring flow field, especially for the processing of ultrafine powders, effectively reducing mixing dead zones and promoting uniform coating of insulating resin.

[0057] Furthermore, the lifting mechanism 4 includes a lifting motor 41, a lead screw 42, a nut 43, and a connecting piece 44; The lifting motor 41 is located outside the mixing tank 1, the lead screw 42 extends vertically, the output shaft of the lifting motor 41 is driven to one end of the lead screw 42 through a coupling, and the nut 43 is sleeved on the lead screw 42 in a screw transmission manner. One end of the connector 44 is connected to the nut 43, and the other end of the connector 44 is installed and connected to the stirring motor 21.

[0058] The lifting mechanism 4 achieves high-precision and stable lifting control of the stirring assembly 2 through a screw and nut transmission mechanism. The lifting motor 41 is located outside the stirring tank 1, effectively isolating the motor operation from temperature fluctuations within the tank, thus ensuring continuous reliability of the lifting operation during temperature control. The screw 42 extends vertically, constraining the verticality of the motion trajectory and preventing lateral deviation during lifting, providing a linear guiding foundation for the stirring assembly 2. The output shaft of the lifting motor 41 is driven to one end of the screw 42 via a coupling. The elastic compensation characteristics of the coupling absorb installation errors and vibrations, ensuring the continuity and smoothness of the rotational power transmission. The nut 43 is screwed onto the screw 42, converting the rotational motion of the lifting motor 41 into precise linear displacement. The self-locking characteristic of its helical pair prevents accidental slippage of the stirring assembly 2 under gravity or stirring resistance, achieving micron-level position control. One end of the connector 44 is connected to the nut 43, and the other end is installed and connected to the stirring motor 21 to form a rigid force transmission path, ensuring that the stirring assembly 2 maintains overall rigidity during the lifting process and avoiding damage to the uniformity of the stirring flow field due to shaking.

[0059] Through the above technical solution, the lifting mechanism 4 can precisely adjust the immersion depth of the stirring component 2 according to process requirements, optimize the action range of the upper stirring paddle 23 and the lower stirring paddle 24 in the material, reduce the agglomeration area of ​​ultrafine magnetic powder, enhance the three-dimensional mixing capability, thereby alleviating the problem of mixing dead zones and providing stable mechanical conditions for uniform coating of insulating resin. At the same time, the lifting mechanism 4 works together with other components of the above-mentioned soft magnetic powder insulation coating device to significantly improve the process stability and coating quality of the equipment when processing ultrafine powder.

[0060] The technical principles of this utility model have been described above with reference to specific embodiments. These descriptions are merely for explaining the principles of this utility model and should not be construed as limiting the scope of protection of this utility model in any way. Based on this explanation, those skilled in the art can readily conceive of other specific embodiments of this utility model without any inventive effort, and these embodiments will all fall within the scope of protection of this utility model.

Claims

1. A device for insulating and coating soft magnetic powder, characterized in that: It includes a mixing tank (1), a mixing assembly (2), a mold temperature controller (3), a temperature sensor, and a control unit. The control unit is communicatively connected to the mixing assembly (2), the mold temperature controller (3), and the temperature sensor, respectively. The temperature sensor is installed inside the mixing tank (1) and is used to detect the real-time temperature of the material; The mixing tank (1) includes an outer tank (11) and an inner tank (12). A sandwich space (13) is formed between the outer tank (11) and the inner tank (12). A heat exchange pipe (14) is provided in the sandwich space (13). The inlet and outlet of the heat exchange pipe (14) are connected to the mold temperature controller (3) through pipelines to form a closed loop. The mold temperature controller (3) is used to adjust the temperature of the internal medium flowing through the heat exchange pipe (14) to heat or cool the mixing tank (1). The stirring assembly (2) includes a stirring motor (21), a stirring shaft (22), an upper stirring paddle (23), and a lower stirring paddle (24). The stirring shaft (22) is connected to the output end of the stirring motor (21), and the upper stirring paddle (23) and the lower stirring paddle (24) are respectively installed on the stirring shaft (22). The stirring assembly (2) is used to stir the material in the stirring tank (1).

2. The apparatus for soft magnetic powder insulation coating according to claim 1, characterized in that: The mold temperature controller (3) includes a heating module (31), a cooling module (32), and a circulating pump (33); The heat exchange pipe (14) includes a hot circulation pipe (141) and a cold circulation pipe (142), which are independent of each other; The inlet and outlet of the heat circulation pipe (141) are connected to the heating module (31) through the first pipe (310) to form a heat circulation loop. The circulation pump (33) is used to drive the internal medium of the heating module (31) to circulate in the heat circulation loop. The inlet and outlet of the cold circulation pipe (142) are connected to the cooling module (32) through the second pipe (320) to form a cold circulation loop. The circulation pump (33) is used to drive the internal medium of the cooling module (32) to circulate in the cold circulation loop.

3. The apparatus for soft magnetic powder insulation coating according to claim 2, characterized in that: The hot circulation pipe (141) and the cold circulation pipe (142) are both spirally wound in the interlayer space (13), and the hot circulation pipe (141) and the cold circulation pipe (142) are alternately arranged in the height direction of the mixing tank (1).

4. The apparatus for soft magnetic powder insulation coating according to claim 1, characterized in that: The upper stirring paddle (23) is positioned above the lower stirring paddle (24). The diameter of the upper stirring paddle (23) is D1, and the diameter of the lower stirring paddle (24) is D2, wherein 1≤D1 / D2≤1.

2.

5. The apparatus for soft magnetic powder insulation coating according to claim 4, characterized in that: The upper stirring paddle (23) and the lower stirring paddle (24) have the same structure, including a stirring hub (201) and a plurality of stirring blades (202). The stirring hub (201) is sleeved on the stirring shaft (22), and the plurality of stirring blades (202) are spaced apart on the outer edge of the stirring hub (201). The stirring blades (202) are inclined in the vertical direction. The upper stirring blade (23) is used to generate an axial hydrodynamic field, and the lower stirring blade (24) is used to generate a radial hydrodynamic field.

6. The apparatus for soft magnetic powder insulation coating according to claim 5, characterized in that: The stirring blade (202) includes a connecting end (2021), a lower edge of the blade (2022), an upper edge of the blade (2023), and an outer edge of the blade (2024). The connecting end (2021) is inclined and fixed to the outer edge of the stirring hub (201). One end of the lower edge (2022) of the blade is connected to the lower end of the connecting end (2021), one end of the upper edge (2023) of the blade is connected to the upper end of the connecting end (2021), the other end of the lower edge (2022) of the blade is connected to the lower end of the outer edge (2024) of the blade, and the other end of the upper edge (2023) of the blade is connected to the upper end of the outer edge (2024) of the blade.

7. The apparatus for soft magnetic powder insulation coating according to claim 6, characterized in that: The angle between the stirring blade (202) of the upper stirring paddle (23) and the horizontal plane is in the range of 30°~45°.

8. The apparatus for soft magnetic powder insulation coating according to claim 6, characterized in that: The angle between the stirring blade (202) of the lower stirring paddle (24) and the horizontal plane is in the range of 40°~55°.

9. The apparatus for soft magnetic powder insulation coating according to claim 1, characterized in that: It also includes a lifting assembly (4), and the control unit is communicatively connected to the lifting assembly (4); The stirring motor (21) is installed on the drive end of the lifting assembly (4), and the lifting assembly (4) is used to control the stirring assembly (2) to rise or fall.

10. The apparatus for soft magnetic powder insulation coating according to claim 9, characterized in that: The lifting assembly (4) includes a lifting motor (41), a lead screw (42), a nut (43), and a connector (44). The lifting motor (41) is located outside the mixing tank (1), the lead screw (42) extends vertically, the output shaft of the lifting motor (41) is driven to one end of the lead screw (42) through a coupling, and the nut (43) is sleeved on the lead screw (42) in a spiral transmission manner. One end of the connector (44) is connected to the nut (43), and the other end of the connector (44) is connected to the stirring motor (21).

Images