Magnet Embedded Core Flash Prevention via Annular Recess

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Solution Overview

Problem

The existing manufacturing devices for magnet embedded cores often result in resin flash during the curing process, leading to surface flaws and leakage, as well as wastage and improper filling of magnet insertion holes due to flash formation.

Innovation Solution

A manufacturing device with an annular recess at the boundary between the base and separator plate, which communicates with the resin pot chamber, prevents flash formation by causing the molten resin to solidify faster in the recess, thereby minimizing wastage and ensuring proper filling of magnet insertion holes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If molten resin is pressed into magnet insertion holes using a plunger, then the magnet insertion holes can be properly filled with resin, but resin may pass into the gap between the base and separator plate and solidify to create flash

Engineering Contradiction:

Improvefilling quality of magnet insertion holesVSAvoidflash creation

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The harmful factor (resin flowing into the gap) is extracted and isolated by introducing an annular recess that captures excess resin before it can enter the gap between the base and separator plate. The recess acts as a separate containment zone that prevents the harmful flow path.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The annular recess serves as an intermediary structure between the resin pot chamber and the gap area. It mediates the resin flow by providing an intermediate zone where excess resin can be contained and solidified without causing flash on the base surface.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If resin is pressed under pressure into magnet insertion holes, then proper filling is achieved, but flash may deposit on the base causing surface flaws and resin leakage

Engineering Contradiction:

Improveresin filling completenessVSAvoidsurface quality and leakage prevention

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The problematic resin flow (excess resin that would cause surface flaws and leakage) is extracted and redirected into the annular recess, separating it from the main product area. This prevents the harmful effects while maintaining the beneficial pressure filling.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The excess resin flow, which would normally be harmful causing flash and leakage, is converted into a beneficial feature by directing it into the annular recess where it solidifies to form a sealing structure. The harmful overflow becomes a useful sealing element.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If flash is created during resin pressing, then resin can be charged into magnet insertion holes, but the flash breaks up and mixes with molten resin causing improper filling

Engineering Contradiction:

Improveresin charging capabilityVSAvoidproper filling of magnet insertion holes

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The flash formation is extracted and isolated in the annular recess, preventing it from mixing with the molten resin in the magnet insertion holes. The recess creates a separate zone where flash can form without contaminating the product.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The annular recess acts as an intermediary barrier that prevents direct contact between the flash and the molten resin in the magnet insertion holes. This mediator structure maintains the separation between the charging process and the flash formation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution effectively prevents flash creation, avoiding surface flaws and leakage, and ensures that the resin is properly filled into the magnet insertion holes, thus enhancing the manufacturing process's reliability and efficiency.

Implementation Method 1

the molten resin may pass from the resin pot chamber into the gap between the upper surface of the base and the lower surface of the separator plate, and solidify therein to create thin flash

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS11588384B2Device and method for manufacturing magnet embedded core

Publication Date: 2023.02.21 KURODA PRECISION INDS

AI summary

In manufacturing a magnet embedded core, creation of flash, and problems associated with flash are prevented. A device for manufacturing the magnet embedded core comprises a base (32) comprising an upper surface at which a resin pot chamber (64) for storing molten resin opens, a separator plate (36) detachably placed on the upper surface of the base (32) to support a rotor core (2) thereon and having a gate (50) and a cull opening (52) communicating the magnet insertion hole (4) of the rotor core (2) with the resin pot chamber (64), and a plunger (62) movably provided in the resin pot chamber (64) to press the molten resin in the resin pot chamber (64) into the magnet insertion hole (4) via the gate (50) and the cull opening (52), wherein an annular recess (66) is formed on the upper surface of the base (32) so as to extend outward of the resin pot chamber (64) and communicate with the resin pot chamber (64).