Amorphous Foil Magnetic Iron Core Resin Spacer Design
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Solution Overview
Problem
Conventional iron cores for rotating and static electrical machines face challenges in achieving high strength, reduced manufacturing time, and cost-effective production, particularly with amorphous foil strips, which are difficult to shape and require lengthy resin impregnation processes.
Innovation Solution
A magnetic iron core is formed by winding amorphous foil strips with resin-filled gaps, using spacers to enhance strength and efficiency, and then molded to achieve a high packing factor, allowing for efficient cutting and application in electrical machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If amorphous foil strips are used to form an iron core, then magnetic loss is reduced and efficiency is improved, but the iron core lacks sufficient strength and is difficult to handle
Solution Approach 1:
The patent combines amorphous foil strips with resin to create a composite iron core structure. The resin impregnation binds the thin foil strips together, providing mechanical strength while preserving the low magnetic loss properties of the amorphous material. This composite approach allows the iron core to be both efficient and handleable.
2Strength
If resin impregnation is performed in vacuum or reduced-pressure atmosphere to strengthen the iron core, then iron core strength is improved, but manufacturing time increases significantly
Solution Approach 1:
The patent employs a disposable spacer that is removed after serving its purpose of maintaining gap uniformity during resin impregnation. This spacer enables the use of simpler, faster atmospheric pressure impregnation methods instead of time-consuming vacuum processes, while still achieving sufficient resin penetration and iron core strengthening.
3Adaptability or versatility
If the iron core is designed with opposed surfaces on two planes along the axial direction, then amorphous metal can be utilized, but manufacturing complexity increases due to cutting requirements
Solution Approach 1:
The patent incorporates spacers during the winding process to pre-establish uniform gaps between foil strips. This preliminary action ensures that subsequent resin impregnation can proceed efficiently under atmospheric pressure, eliminating the need for complex vacuum equipment and reducing manufacturing steps.
Solution Approach 2:
The spacer acts as an intermediary tool during manufacturing. It temporarily maintains the required gap structure during winding and impregnation, then is removed after serving its purpose. This intermediary element simplifies the overall manufacturing process by enabling the use of simpler impregnation methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a high-quality, efficient, and cost-effective magnetic iron core with improved strength and reduced manufacturing time, suitable for both rotating and static electrical machines, enhancing their performance and miniaturization.
Implementation Method 1
the resin being disposed in every plural turns of windings of the amorphous foil strip
Implementation Method 2
An amorphous metal has low iron-loss characteristics belonging in the top class among soft magnetic materials
Implementation Method 3
By winding an amorphous foil strip, an iron core can be kept high in strength. Therefore, it is possible to redirect a flow direction of magnetic fluxes
Data Source
AI summary
The magnetic iron core includes an amorphous foil strip wound to form the magnetic iron core. Preferably, the magnetic iron core is filled with resin, the resin being disposed by using a spacer between pluralities of windings of the amorphous foil strip. Preferably, the magnetic iron core is covered with resin integrated with and continuous to the resin disposed between pluralities of windings of the amorphous foil strip.