Magnetic Encoder Zinc-Aluminum-Magnesium Plating Adhesion
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Solution Overview
Problem
Magnetic encoders using cold rolled steel plates with hot-dip zinc-aluminum-magnesium alloy plating face issues with low adhesive strength between the plated layer and the adhesive layer, leading to poor durability, especially in outdoor environments where corrosion is a concern.
Innovation Solution
A magnetic encoder design that includes a cold rolled steel plate core with a zinc-aluminum-magnesium alloy plated layer, a phosphoric acid salt film layer, and an adhesive layer, which improves the stability of the adhesive strength and prevents corrosion product generation, using phenol-based or epoxy-based adhesives and a silane-based or epoxy-based primer for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hot-dip zinc-aluminum-magnesium alloy plating is applied to cold rolled steel plate to improve corrosion resistance, then corrosion resistance is improved, but adhesive strength between plated layer and adhesive layer deteriorates
Solution Approach 1:
A phosphoric acid salt film layer is introduced as an intermediary between the zinc-aluminum-magnesium alloy plated layer and the adhesive layer. This intermediate layer serves as a bonding bridge that maintains both corrosion resistance and adhesive strength, resolving the contradiction by adding a mediating substance that facilitates both functions simultaneously.
Solution Approach 2:
The solution creates a composite structure consisting of multiple layers: the cold rolled steel plate core, the zinc-aluminum-magnesium alloy plated layer for corrosion protection, the phosphoric acid salt film layer for bonding enhancement, and the adhesive layer. This composite material approach allows each layer to fulfill its specific function while working together to achieve both corrosion resistance and adhesive strength.
2Quantity of substance
If cold rolled steel plate is used for core metal to reduce material cost, then material cost is reduced, but corrosion resistance deteriorates
Solution Approach 1:
The solution creates a composite structure consisting of multiple layers: the cold rolled steel plate core, the zinc-aluminum-magnesium alloy plated layer for corrosion protection, the phosphoric acid salt film layer for bonding enhancement, and the adhesive layer. This composite material approach allows each layer to fulfill its specific function while working together to achieve both corrosion resistance and adhesive strength.
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 provides a magnetic encoder with improved adhesive strength and corrosion resistance, allowing it to withstand long-term use in outdoor environments without peeling of the plastic magnet section, even when exposed to high-speed rotation and corrosive conditions.
Implementation Method 1
by forming a film of a phosphoric acid salt on a surface of a plated layer including a zinc-aluminum-magnesium alloy
Implementation Method 2
an adhesive layer stacked on the phosphoric acid salt film layer
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
Disclosed is a magnetic encoder having, as a core metal, a cold rolled steel plate subjected to hot-dip zinc plating, the magnetic encoder being excellent in stability of adhesive strength between a plated layer and an adhesive layer, and a method for efficiently producing the magnetic encoder. The magnetic encoder includes a core metal made of a cold rolled steel plate; a substantially annular plastic magnet section magnetized multi-polarly in a circumferential direction; a plated layer containing a zinc-aluminum-magnesium alloy stacked on a surface of the core metal; a phosphoric acid salt film layer stacked on a surface of the plated layer; an adhesive layer stacked on the phosphoric acid salt film layer; and a plastic magnet layer stacked on the adhesive layer.