Permanent Magnet Assembly Bonding and Coating Process
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Solution Overview
Problem
The manufacturing of high-performance permanent magnets for hybrid electric vehicles is hindered by issues such as increased temperature due to eddy currents, irreversible demagnetization, high manufacturing costs, and reduced productivity, particularly with rare-earth magnets, which require additional processing steps like surface grinding and coating.
Innovation Solution
An apparatus and method that simultaneously bonds and coats permanent magnet blocks using a thermosetting resin adhesive, applied evenly through recirculating molds made of rubber, eliminating the need for surface grinding and coating processes, thereby reducing temperature increases and manufacturing costs while improving corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rare-earth permanent magnets are used to reduce motor weight and improve efficiency, then magnetic force is improved, but temperature increases due to eddy currents causing demagnetization
Solution Approach 1:
The permanent magnet is divided into multiple blocks arranged in an array, with non-magnetic material layers inserted between adjacent blocks. This segmentation interrupts eddy current paths, reducing temperature increase while maintaining the overall magnetic force of the motor.
2Temperature
If permanent magnets are divided axially or laterally to decrease eddy current paths, then temperature increase is reduced, but productivity deteriorates due to additional bonding and post-treatment processes
Solution Approach 1:
The bonding process and coating process are merged into a single simultaneous operation. Adhesive is applied to bonding surfaces of permanent magnet blocks, and coating material is applied to outer surfaces exposed to the stator, all in one step, eliminating sequential processing and improving productivity.
Solution Approach 2:
The adhesive serves multiple functions: it bonds permanent magnet blocks together and simultaneously provides corrosion-resistant coating on bonding surfaces. This multi-functionality eliminates the need for separate bonding and coating processes.
3Ease of manufacture
If bonding layers are formed on bonding surfaces of permanent magnets, then manufacturing complexity increases, but productivity decreases due to required post-treatment processes
Solution Approach 1:
Bonding and coating operations are combined into a single simultaneous process step, where adhesive application and coating material application occur together, eliminating multiple sequential steps and improving production rate.
Solution Approach 2:
Adhesive is pre-applied to bonding surfaces before final assembly, and coating material is pre-applied to outer surfaces, so that both bonding and coating are completed in advance during the manufacturing process itself, eliminating post-treatment operations.
4Manufacturing precision
If surface grinding is performed to adjust flatness, then manufacturing precision is improved, but production quality deteriorates due to corner breakage
Solution Approach 1:
Flatness is adjusted during the bonding process itself by applying pressure to level the permanent magnet blocks before adhesive hardening, rather than performing surface grinding after assembly. This preliminary action prevents corner breakage while achieving required flatness.
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 simplifies the manufacturing process, reduces costs, and enhances the performance and corrosion resistance of permanent magnets by minimizing adhesive usage and eliminating post-treatment processes, leading to improved durability and productivity.
Implementation Method 1
integrating the plurality of permanent magnet blocks such that the adhesive is evenly applied to a surface of each of the permanent magnet blocks, thereby forming a permanent magnet assembly
Implementation Method 2
hardening the adhesive by heating the permanent magnet assembly
Data Source
AI summary
A method for manufacturing a permanent magnet includes preparing a plurality of permanent magnet blocks having the same size, spacing and arranging the plurality of permanent magnet blocks in a lower mold Having an opened upper side, pressing a side of the lower mold while circulating adhesive in the lower mold and integrating the plurality of permanent magnet blocks such that the adhesive is evenly applied to surface of each of the permanent magnet blocks, thereby forming a permanent magnet assembly and hardening the adhesive by heating the permanent magnet assembly.