Rare Earth Magnet Composite Molding Without Resin Contact
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Solution Overview
Problem
Injection molding of rare earth magnets with resin leads to deterioration of magnetic properties due to direct contact and resin shrinkage creating gaps, preventing complete coverage.
Innovation Solution
A method involving a first molded body covering the rare earth magnet, followed by injection-molding a thermoplastic resin to cover the remaining surface, ensuring the magnet does not directly contact the resin, thereby reducing heat-induced deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If injection molding is performed directly on a rare earth magnet, then the magnet can be covered with resin for corrosion prevention, but the magnetic properties of the permanent magnet deteriorate due to heat
Solution Approach 1:
The patent introduces a first molded body as an intermediary component between the rare earth magnet and the injection-molded resin. This first molded body covers the entire surface of the rare earth magnet, preventing direct contact with the hot resin during injection molding. The intermediary structure allows the resin to provide corrosion protection while the first molded body acts as a thermal barrier, resolving the contradiction between achieving complete coverage and preventing heat-induced magnetic property deterioration.
2Reliability
If injection molding is performed to cover the magnet, then corrosion protection is achieved, but shrinkage creates gaps between the spacer and magnet, failing to completely cover the magnet
Solution Approach 1:
The patent employs preliminary action by first forming a first molded body that precisely fits and covers the entire surface of the rare earth magnet before the injection molding process. This pre-formed protective layer ensures that when the resin is subsequently injection-molded, any shrinkage occurs in the resin layer rather than creating gaps between the magnet and the covering material. The preliminary coverage maintains manufacturing precision and ensures complete coverage throughout the corrosion prevention process.
3Ease of manufacture
If a single-layer resin coating is applied to the magnet, then the process is simple, but the resin shrinks after molding creating gaps that fail to provide complete coverage
Solution Approach 1:
The patent divides the protective coating into two segmented layers: a first molded body that directly contacts and covers the rare earth magnet, and a second injection-molded resin layer that provides additional corrosion protection. This segmentation allows each layer to perform its specific function - the first molded body ensures precise coverage and thermal protection, while the second layer provides bulk corrosion resistance. The segmented structure resolves the contradiction by maintaining process relative simplicity while achieving complete coverage without shrinkage gaps.
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 produces a composite component with sealed rare earth magnets, maintaining magnetic properties and enhancing environmental resistance.
Implementation Method 1
forming a second molded body by inserting the second composite into a mold and injection-molding a thermoplastic resin
Data Source
AI summary
The present invention relates to a method of producing a composite component, the method including: preparing a second composite by fitting a first molded body onto a first composite including a rare earth magnet and a component contacting the rare earth magnet, such that the first molded body covers at least the entire surface of the first composite corresponding to the rare earth magnet; and forming a second molded body by inserting the second composite into a mold and injection-molding a thermoplastic resin such that the thermoplastic resin covers at least the entire surface of the first composite not covered by the first molded body and also contacts the first molded body.