Laminated Core Resin Injection Gate Hole Design
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Solution Overview
Problem
The existing method of resin-sealing permanent magnets in laminated cores using a dummy plate often results in dents on the surface due to the removal of residual resin, which reduces the pore diameter of the gate hole, leading to incomplete filling of magnet insertion holes and difficulties in cleaning, thereby preventing repeated use of the dummy plate.
Innovation Solution
A method involving a dummy plate with gate holes that overlap both the magnet insertion holes and the core body surface, allowing resin to be injected efficiently and facilitating easy removal of the dummy plate without denting the resin, by optimizing the overlap region and shape of the gate holes to ensure complete filling and easy cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pore diameter of the gate hole is reduced to prevent resin dents, then the resin flow rate is reduced, but the magnet insertion hole cannot be filled up with resin within the predetermined period
Solution Approach 1:
The gate hole is divided into two distinct parts: a first pore in the dummy plate and a second pore in the core body. This segmentation allows each pore to be optimized independently - the first pore can be larger to maintain resin flow rate, while the second pore controls resin entry to prevent dents, thus resolving the contradiction between filling speed and surface quality.
Solution Approach 2:
Different pore diameters are applied at different locations in the resin flow path. The first pore (in dummy plate) has a larger diameter to ensure adequate resin flow rate, while the second pore (in core body) has a smaller diameter to control resin entry and prevent surface dents. This local differentiation resolves the contradiction by optimizing each location's pore size for its specific function.
2Manufacturing precision
If the pore diameter of the gate hole is reduced to prevent resin dents, then resin flow rate is reduced, but complete filling of magnet insertion hole cannot be achieved
Solution Approach 1:
The gate hole is divided into a first pore in the dummy plate and a second pore in the core body. The first pore maintains larger diameter to ensure sufficient resin volume flows through, while the second pore's smaller diameter prevents surface dents. This segmentation resolves the contradiction between preventing dents and ensuring complete filling.
Solution Approach 2:
Different pore diameters are applied at different locations: the first pore (dummy plate side) has larger diameter to supply adequate resin volume, while the second pore (core body side) has smaller diameter to prevent surface defects. This local optimization resolves the contradiction between surface quality and resin quantity.
3Manufacturing precision
If the pore diameter of the gate hole is reduced, then it becomes difficult to remove residual resin from the dummy plate and clean the gate hole
Solution Approach 1:
The gate hole is segmented into a first pore in the dummy plate and a second pore in the core body. The first pore maintains a larger diameter that facilitates easy removal of residual resin and cleaning operations, while the second pore's smaller diameter prevents surface dents. This segmentation resolves the contradiction between surface quality and ease of maintenance.
Solution Approach 2:
Different pore diameters are applied at different locations: the first pore (dummy plate) has larger diameter for easy cleaning and residual resin removal, while the second pore (core body) has smaller diameter to prevent surface defects. This local differentiation resolves the contradiction between surface quality and manufacturability.
4Manufacturing precision
If the pore diameter of the gate hole is reduced, then the dummy plate cannot be reused in manufacture of laminated core
Solution Approach 1:
The gate hole is divided into a first pore in the dummy plate and a second pore in the core body. The first pore maintains a larger diameter that allows easy removal of residual resin, enabling dummy plate reuse, while the second pore prevents surface dents. This segmentation resolves the contradiction between surface quality and reusability.
Solution Approach 2:
Different pore diameters are applied at different locations: the first pore (dummy plate) has larger diameter to facilitate residual resin removal for reuse, while the second pore (core body) has smaller diameter to prevent surface defects. This local optimization resolves the contradiction between surface quality and adaptability.
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 method prevents resin dents, ensures complete filling of magnet insertion holes, and allows for the repeated use of the dummy plate by maintaining the resin flow rate and amount, while facilitating the removal of residual resin and cleaning of the gate holes.
Implementation Method 1
injecting a resin from resin reservoir pots into the magnet insertion holes to fix the permanent magnets
Data Source
AI summary
A method of manufacturing a laminated core includes inserting permanent magnets 14 into magnet insertion holes 12, 12a of a core body 13; injecting a resin 18 into the holes 12, 12a from resin reservoir pots 17 in the die 15 (16) to fix the magnets 14; placing a dummy plate 19 between the die 15 having the pots 17 and the body 13, the plate 19 having gate holes 35, 35a guiding the resin 18 from the pots 17 into the holes 12, 12a, the hole 35 (35a) overlapping with both of a part of the hole 12 (12a) and a surface of the body 13; poring the resin 18 via the holes 35, 35a and curing the resin 18 in the holes 12, 12a; and separating the plate 19 from the body 13 to remove the resin 18 overflowed from the holes 12, 12a.