Dust Core Compound Composition for High Crushing Strength
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Solution Overview
Problem
The internal lubrication method for producing dust cores results in lower crushing strength compared to the die lubrication method, and is limited by the shape complexity of the core, making it difficult to achieve high mechanical strength, especially for cores with complicated or thin-walled shapes.
Innovation Solution
A compound comprising a metal powder, a resin composition, and a metal salt represented by R2M, where R is a saturated fatty acid group with 6 to 12 carbon atoms and M is a divalent metal element between Ca and Ba, is used to enhance the mechanical strength of dust cores, allowing for high radial crushing strength even in complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If internal lubrication method is used to produce dust cores, then manufacturing ease is improved, but mechanical strength deteriorates
Solution Approach 1:
The invention changes the chemical composition parameters of the lubricating agent by specifying a metal salt with a saturated fatty acid group having 6-12 carbon atoms. This parameter change allows the lubricating agent to provide adequate lubrication while maintaining higher crushing strength compared to conventional lubricating agents like zinc stearate.
Solution Approach 2:
The invention uses a composite lubricating agent system comprising a metal salt combined with a saturated fatty acid group. This composite material provides both the lubrication function needed for internal lubrication method and the mechanical strength required for complex-shaped dust cores, resolving the contradiction between ease of manufacture and strength.
2Ease of manufacture
If common lubricating agent such as zinc stearate is added to compound, then ease of manufacture is improved, but mechanical strength deteriorates
Solution Approach 1:
The invention changes the molecular structure parameters of the lubricating agent by specifying a saturated fatty acid group with 6-12 carbon atoms. This parameter change creates a lubricating agent that maintains effectiveness at lower concentrations while preserving mechanical strength, unlike zinc stearate which requires higher concentrations and significantly weakens the dust core.
3Strength
If die lubrication method is used to produce dust cores, then mechanical strength is improved, but adaptability deteriorates
Solution Approach 1:
The invention introduces a specially designed metal salt lubricating agent as an intermediary substance within the compound. This intermediary provides the necessary lubrication function internally, enabling the production of complex-shaped dust cores that would otherwise require die lubrication method, thus expanding adaptability while maintaining mechanical strength.
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 compound enables the production of dust cores with increased mechanical strength, including radial crushing strength, and improved rust resistance, particularly for annular or tubular shapes, while maintaining excellent flowability and mold releasability.
Implementation Method 1
a lubricating agent is not mixed with raw materials (compound), and a dust core is obtained by compacting of a compound using a die that has been coated in advance with a lubricating agent
Implementation Method 2
a resin composition, and a metal salt
Data Source
AI summary
A compound for dust core includes a metal powder including iron, a resin composition, and a metal salt, in which the metal salt is represented by R2M, R represents a saturated fatty acid group having 6 or more and 12 or less carbon atoms, and M represents at least one metal element between Ca and Ba.