Embedded Rotor Magnet Formation via Particle Coating
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Solution Overview
Problem
Existing methods for creating magnetic properties in electric motor rotors rely on bonding magnets to the surface, which is less desirable than embedding magnets within the rotor, and there is a need for effective methods to form magnets within the rotor.
Innovation Solution
The methods involve inserting magnetizable particles into the rotor, coating them with a non-metallic material, and magnetizing the particles, either by submerging the rotor in a viscous material or mixing the particles with the material within the rotor, followed by curing and magnetization to ensure uniform coating and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnets are bonded to the surface of the rotor, then the manufacturing process is simpler, but the magnetic performance and rotational stability are inferior compared to embedded magnets
Solution Approach 1:
The patent embeds magnets within the rotor structure by placing magnetizable particles into cavities or apertures formed in the rotor body, then coating and curing them in place. This nesting approach integrates the magnets into the rotor rather than attaching them externally, improving rotational stability while maintaining manufacturing feasibility through a multi-step process involving particle insertion, coating application, and curing.
Solution Approach 2:
The patent applies preliminary actions by first forming cavities in the rotor, then inserting magnetizable particles, coating them with non-metallic material, and curing the coating before final magnetization. This sequence of preliminary steps prepares the rotor structure to securely hold embedded magnets, achieving both manufacturing feasibility and rotational stability.
2Reliability
If magnetizable particles are embedded within the rotor, then the magnetic performance is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the magnetization process by treating individual magnetizable particles separately - each particle is coated with non-metallic material and then magnetized. This segmentation allows for precise control of each particle's properties while maintaining overall manufacturing feasibility through standardized processes applied to multiple particles.
Solution Approach 2:
The patent uses a non-metallic coating material as an intermediary between the magnetizable particles and the rotor environment. This coating layer facilitates particle insertion, provides electrical insulation, and enables curing to secure particles in place, simplifying the overall manufacturing process while achieving embedded magnetization.
3Manufacturing precision
If particles are coated with non-metallic material and cured, then the particle separation and polarity consistency are improved, but the manufacturing time increases
Solution Approach 1:
The patent changes the physical-chemical parameters of the coating material by applying a non-metallic coating and then curing it. This parameter change transforms the coating from a liquid or soft state to a hardened state, securing the particles in place with consistent orientation. The curing process achieves precise polarity consistency while minimizing time loss through efficient parameter transformation.
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
This approach allows for the formation of embedded magnets with consistent polarity orientation, enhancing the magnetic properties of the rotor and improving its rotational performance by ensuring that the magnets are uniformly coated and separated, thus resisting particle attraction and repulsion.
Implementation Method 1
magnetizing the particles
Implementation Method 2
coating the particles with a non-metallic material... ensuring that the magnets are uniformly coated and separated, thus resisting particle attraction and repulsion
Data Source
AI summary
Methods are provided for forming/inserting a magnet in a rotor. One method includes coating a plurality of magnetizable particles with a non-metallic material, inserting the coated particles in a rotor, and magnetizing the coated particles. Another method includes inserting a plurality of magnetizable particles into a rotor, submersing the rotor in motor varnish or another viscous, non-metallic material to coat the particles, and magnetizing the particles. Yet another method includes inserting a plurality of magnetizable particles in a rotor, inserting a non-metallic material into the rotor, mixing the particles and non-metallic material to form a mixture, curing the mixture to coat each particle with non-metallic material, and magnetizing the particles. Still another method includes mixing a plurality of magnetizable particles with a non-metallic material, curing the non-metallic material to coat each particle with non-metallic material, inserting the coated particles in a rotor, and magnetizing the coated particles.