Integral Magnetic Element Structure for Eddy Current Blocking
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Solution Overview
Problem
Existing magnetic element manufacturing methods for electric motors face challenges such as increased costs, laborious processes, and low material utilization due to segmentation, adhesive requirements, and poor insulation performance, which lead to eddy current losses and heating issues.
Innovation Solution
A magnetic element with multiple units arranged in sequence, featuring grooves and connecting portions made of the same material, integrated into a one-piece structure to block eddy current paths, eliminating the need for segmentation and adhesive bonding, and allowing for efficient production and improved material utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If magnetic segments are segmented and stacked to reduce eddy current loss, then eddy current loss is reduced, but manufacturing process becomes cumbersome and time-consuming
Solution Approach 1:
The patent merges multiple magnetic segments into a single integral magnetic element with through holes, eliminating the need for separate stacking and bonding processes while maintaining eddy current reduction functionality
Solution Approach 2:
The integral magnetic element incorporates through holes that segment the magnetic material internally to block eddy current paths, achieving the benefits of segmentation without requiring external assembly of multiple pieces
2Loss of energy
If magnetic segments are segmented and stacked to reduce eddy current loss, then eddy current loss is reduced, but manufacturing cost increases due to adhesive use
Solution Approach 1:
The patent combines multiple magnetic segments into one integral piece, eliminating the need for adhesives and associated materials while maintaining the eddy current blocking function through strategically positioned through holes
Solution Approach 2:
The patent extracts and removes the adhesive bonding step from the manufacturing process by designing an integral structure where through holes provide the necessary eddy current path blocking without requiring external bonding agents
3Loss of energy
If magnetic segments are segmented to reduce eddy current loss, then eddy current loss is reduced, but material utilization rate decreases due to scrap materials
Solution Approach 1:
The patent merges multiple segmented pieces into a single integral magnetic element, allowing the entire component to be manufactured from one continuous piece of material and thereby minimizing or eliminating scrap generation during the manufacturing process
4Reliability
If insulation layer is sprayed on segmented magnetic segments, then insulation is provided, but adhesion performance is poor and efficiency decreases
Solution Approach 1:
The patent combines all magnetic segments into one integral piece with through holes, providing a continuous surface for insulation coating application that improves adhesion and allows for more efficient coating processes compared to treating multiple separate segments
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 solution reduces eddy current losses, enhances production efficiency, minimizes scrap materials, and eliminates the need for adhesives, resulting in a cost-effective and structurally stable magnetic element suitable for various electromagnetic devices.
Implementation Method 1
When a magnetic element, such as a magnet, moves in a non-uniform magnetic field or is in a time-varying magnetic field, the current induced in the magnetic element leads to energy loss, which is called eddy current loss
Data Source
AI summary
A magnetic element includes a plurality of magnetic units, where the plurality of magnetic units are arranged in sequence; a groove and a connecting portion are provided between adjacent magnetic units; the grooves are used for blocking an eddy current path; the connecting portions connect adjacent magnetic units; and the connecting portions are connected to the grooves and prevent the grooves from completely penetrating through adjacent magnetic units. The connecting portions and the magnetic units are made of the same material and are integrally formed, such that the overlapping and bonding processes are omitted, the production efficiency of the magnetic element is effectively improved.