Dummy Plate Gate Hole Design for Resin Injection
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Solution Overview
Problem
The increased number of permanent magnets in armatures leads to a higher number of gate holes and flow paths in dummy plates, resulting in increased resin residue and higher material costs and removal efforts during the manufacturing process.
Innovation Solution
A dummy plate with a gate hole that partially overlaps with multiple magnet-insert holes, reducing the number of gate holes and flow paths, allowing resin to be injected efficiently while minimizing resin residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of permanent magnets is increased to improve electromagnetic performance, then the electromagnetic performance is improved, but the number of gate holes and flow paths must be increased which leads to increased resin residue and material waste
Solution Approach 1:
The patent merges multiple flow paths into a single shared flow path that serves multiple magnet insert holes. Instead of providing separate gate holes and flow paths for each permanent magnet, the invention designs one flow path that distributes resin to multiple holes, thereby reducing the total number of flow paths and gate holes while still accommodating an increased number of permanent magnets for improved electromagnetic performance
Solution Approach 2:
The single flow path is designed to serve multiple functions by distributing resin to multiple magnet insert holes simultaneously. This multi-functional flow path structure allows the same flow path to support an increased number of permanent magnets without requiring proportional increases in the number of gate holes and flow paths, thus reducing resin residue while maintaining improved electromagnetic performance
2Quantity of substance
If the number of gate holes is increased to accommodate more permanent magnets, then more permanent magnets can be inserted, but the number of flow paths must be increased which increases device complexity and resin residue
Solution Approach 1:
The patent combines multiple flow paths into one shared flow path that distributes resin to multiple magnet insert holes. This merging approach allows the system to accommodate an increased quantity of permanent magnets without proportionally increasing the number of flow paths, thereby reducing device complexity while maintaining the capability to insert more permanent magnets
Solution Approach 2:
The invention introduces a dimensional change in the flow path structure by creating a multi-branch distribution system within a single flow path. Instead of increasing the number of separate flow paths in the planar dimension, the design uses a hierarchical distribution structure where one flow path branches out to multiple holes, effectively accommodating more permanent magnets without increasing overall device complexity
3Productivity
If multiple flow paths are provided to inject resin into multiple magnet-insert holes, then resin can be injected simultaneously, but resin residue increases and removal efforts increase
Solution Approach 1:
The patent merges multiple flow paths into a single flow path that distributes resin to multiple magnet insert holes. This consolidation maintains simultaneous resin injection capability (productivity) while reducing the total number of flow paths, thereby minimizing resin residue that would otherwise accumulate in multiple separate flow paths and requiring extensive removal efforts
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
Decreases the amount of resin residue on the dummy plate, reduces removal efforts, and minimizes material waste, thereby improving the yield rate of resin material.
Implementation Method 1
a resin stored in the resin pool pot flows into magnet-insert holes through the gate hole
Implementation Method 2
the resin is cured inside the plurality of magnet-insert holes to fix the permanent magnets to the laminated iron core
Data Source
AI summary
In a case where a permanent magnet is inserted into each of a plurality of magnet-insert holes of a laminated iron core and then a resin is injected into the plurality of magnet-insert holes from a resin pool pot formed in one of an upper die and a lower die with the laminated iron core pinched and the resin is cured inside the plurality of magnet-insert holes to fix the permanent magnets to the laminated iron core, a dummy plate which abuts on the laminated iron core and includes a gate hole for allowing passage of the resin delivered from the resin pool pot and guiding the resin to the plurality of magnet-insert holes. The gate hole partially overlaps with at least two of the plurality of magnet-insert holes in a plan view of the dummy plate and the laminated iron core.