Inkjet UV Resin Coating for Rare Earth Magnet Insulation
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Solution Overview
Problem
Conventional surface treatment methods for Nd—Fe—B sintered magnets, such as spray coating and electrodeposition, are costly and inefficient, leading to non-uniform corrosion resistance and insulation, which can result in heat loss and magnetic property deterioration, affecting the performance of electric motors.
Innovation Solution
A method using an inkjet system to apply UV curable resin droplets onto the magnet surface, followed by UV curing, forming a homogeneous coating film that provides corrosion resistance and insulation, reducing waste and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spray coating or electrodeposition coating is used to form a coating film on the magnet surface, then corrosion resistance and insulation are improved, but manufacturing cost and energy consumption increase due to required heating equipment and long curing time
Solution Approach 1:
The patent changes the curing method from thermal curing (heating) to UV light curing. The coating composition is formulated to be curable by UV irradiation, transforming the energy parameter from thermal to optical, thereby eliminating the need for heating equipment and reducing energy consumption while maintaining corrosion resistance
Solution Approach 2:
The patent replaces the thermal field system (heating furnace) with an optical field system (UV light source). The coating is designed to cure under UV irradiation instead of heat, substituting the mechanical/thermal curing process with a photochemical curing process, which eliminates large heating equipment and reduces energy consumption
2Reliability
If spray coating is used to apply coating material, then coverage is achieved, but material loss increases and yield decreases due to spraying inefficiency
Solution Approach 1:
The patent extracts the excess material loss inherent in spray coating by adopting a direct application method. The coating composition is applied directly to the magnet surface without aerosolization, eliminating the material loss that occurs during spray atomization and delivery, thereby improving material yield while maintaining protective coverage
Solution Approach 2:
The patent uses a transparent or translucent coating composition that allows visual inspection of the magnet surface. This enables verification of complete coverage and uniform thickness without requiring excess material, as the coating's optical properties allow direct observation of the underlying surface through the cured film
3Reliability
If conventional coating methods are used, then coating film is formed, but manufacturing time increases due to long heating and curing processes
Solution Approach 1:
The patent changes the curing activation parameter from temperature (thermal energy) to UV light wavelength (optical energy). This parameter transformation enables rapid curing through photochemical reaction, reducing the time required from hours or minutes of heating to seconds of UV irradiation, thereby maintaining insulation properties while significantly reducing manufacturing time
Solution Approach 2:
The patent employs periodic UV irradiation to cure the coating. The UV light source is applied in controlled intervals or sequences, allowing efficient curing without continuous energy input, thereby reducing total curing time while ensuring complete polymerization and formation of the insulating coating film
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 method efficiently forms a uniform coating film on rare earth magnets, enhancing corrosion resistance and insulation while reducing costs and energy consumption, thereby improving the performance of electric motors.
Implementation Method 1
irradiating the UV curable resin composition with UV light to cure the UV curable resin composition
Data Source
AI summary
Provided is a rare earth magnet, on the surface of which a coating film of an ultraviolet cured resin is formed by covering the surface of the rare earth magnet with an ultraviolet curable resin composition and subsequently curing the ultraviolet curable resin composition by irradiating the ultraviolet curable resin composition with ultraviolet light. With respect to this rare earth magnet, the coating film is formed by a method which comprises: a step for having droplets of the ultraviolet curable resin composition adhere to the rare earth magnet surface by ejecting the droplets of the ultraviolet curable resin composition from a tip of a head by an inkjet method wherein droplets are ejected from a head; and a step for curing the ultraviolet curable resin composition by irradiating the ultraviolet curable resin composition adhering to the rare earth magnet surface with ultraviolet light.