Magnetic Sheet Slurry Casting With Patterned Carrier Strip Wetting
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Solution Overview
Problem
Conventional methods for producing magnetic sheets for high-power density electrical machines result in significant waste, high manufacturing costs, and limited layer thickness, making it difficult to achieve efficient large-scale production.
Innovation Solution
A process involving the formation of a viscous mass from an inorganic powder, organic binder, and liquid carrier, applied to a carrier tape with distinct liability and flow areas, allowing for the creation of thin magnetic sheets with reduced waste and increased power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnetic laminations are punched out of a continuous coil, then magnetic sheets can be produced, but a very large amount of waste is generated and manufacturing costs are high
Solution Approach 1:
The invention changes the physical state and form of the magnetic material from a continuous coil to a powder-based viscous mass, allowing for near-net-shape printing that minimizes waste. The powder is mixed with organic binder and liquid carrier to create a printable slip that can be directly formed into magnetic sheets of desired thickness and geometry.
Solution Approach 2:
The invention replaces the mechanical punching process with a printing process using a stencil and slip casting. Instead of mechanically cutting sheets from a coil, the magnetic powder is deposited and formed into sheets through a printing mechanism, significantly reducing material waste and enabling more precise dimensional control.
2Power
If magnetic laminations are made thinner to achieve higher power density, then power density increases, but conventional punching methods cannot achieve the required thickness
Solution Approach 1:
The invention replaces the mechanical punching process with a printing process that can achieve much thinner and more precise layer thicknesses. The printing method allows for controlled deposition of the viscous mass in thin layers that can be sintered into magnetic sheets with thicknesses suitable for high-power-density applications.
Solution Approach 2:
The invention transitions from a mechanical cutting process operating in three dimensions to a printing process that builds the magnetic sheets layer by layer, enabling precise control over the thickness dimension. This dimensional approach to manufacturing allows for achieving the required thinness that conventional punching cannot provide.
3Manufacturing precision
If screen printing is used for large-scale series production, then magnetic sheets can be produced with good precision, but very high investment in production facilities is required
Solution Approach 1:
The invention extracts the essential function of shape formation from complex screen printing machinery and achieves it through a simpler stencil-based approach. The stencil serves as a mask that defines the geometry of the magnetic sheets during the slip casting process, eliminating the need for expensive screen printing equipment while maintaining good geometric precision.
Solution Approach 2:
The invention uses a disposable or replaceable stencil instead of expensive, complex screen printing facilities. The stencil can be a simple mask or template that defines the geometry during printing, and can be replaced or modified as needed, significantly reducing the investment in production facilities compared to traditional screen printing equipment.
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 process enables the production of magnetic sheets with thinner layers, higher power density, and reduced waste, facilitating more efficient and cost-effective large-scale manufacturing compared to conventional methods.
Implementation Method 1
an adhesion area essentially depicting a geometry of a magnetic sheet green body and having a contact angle with the slip of less than 50° and a flow area having a contact angle with the slip of more than 100°
Implementation Method 2
an adhesion area essentially depicting a geometry of a magnetic sheet green body and having a contact angle with the slip of less than 50° and a flow area having a contact angle with the slip of more than 100°
Implementation Method 3
drying the slip on the carrier belt, whereby the magnetic sheet green body is created on the adhesion area
Implementation Method 4
sintering the magnetic sheet green body
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a method for producing a magnetic sheet 22 for an electric machine 4, comprising the following steps: - producing a viscous mass (6) in the form of a slurry by mixing at least one inorganic powder (26) with at least one organic binder (28) and a liquid carrier (30), - providing a slurry carrier strip 102, wherein at least two different surface areas 104, 106 are produced on a surface 110 of the carrier strip 102, an adhesion area 104 and a flow area 106, wherein - the adhesion area 104 essentially reflects the geometry of a magnetic sheet green body 8 and - has a contact angle 108 with the slurry 6 that is less than 50° and - the flow area 106 has a contact angle with the slurry 6 that is more than 100°, - applying the slurry 6 to the carrier strip 102,so that the slurry 6 flows from the flow area 106 and adheres to the adhesion area, - drying of the slurry 6 on the carrier belt 102, thereby creating the magnetic sheet green body 6 on the adhesion area 104, - sintering of the magnetic sheet green body.