Magnetically Loaded Composite Rotors Uniform Particulate Distribution
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Solution Overview
Problem
The existing methods for producing magnetically loaded composite (MLC) rotors face issues with clumping of anisotropic NdFeB particulates around the poles of orientation magnets, leading to imbalance and potential destruction of the rotor and stator assembly, especially at high speeds.
Innovation Solution
A method involving a thermoplastic resin impregnated fibre tow and anisotropic magnetically loaded pre-impregnated tape, where a mandrel with an embedded magnetic field is used to align magnetic poles, and heat is applied to bond the tow and tape, forming a magnetically loaded composite tape with reduced clumping and improved magnetic configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermosetting resin slurry is used to impregnate glass fibre tow in MLC rotor production, then the rotor structure can be formed, but the magnetic particulates clump around the poles of orientation magnets causing imbalance
Solution Approach 1:
The patent changes the resin system from thermosetting to thermoplastic, fundamentally altering the material parameters. This enables the magnetic particulates to remain suspended in the molten thermoplastic resin during processing rather than clumping around magnets, achieving uniform distribution and rotor balance
Solution Approach 2:
The patent replaces the chemical curing mechanism of thermosetting resins with the physical melting and solidification process of thermoplastic resins. This substitution allows magnetic particulates to be evenly distributed through the molten resin and frozen in place during cooling, preventing clumping
2Stability of the object's composition
If orientation magnets are used to align magnetic particulates, then magnetic configuration is achieved, but particulate clumping occurs around the magnet poles
Solution Approach 1:
By changing from thermosetting to thermoplastic resin, the patent alters the resin's rheological parameters during processing. The thermoplastic resin remains fluid at processing temperatures, allowing magnetic particulates to be uniformly distributed by the resin flow itself, reducing reliance on orientation magnets and preventing clumping
Solution Approach 2:
The thermoplastic resin acts as an intermediary medium that carries and distributes magnetic particulates uniformly throughout the composite structure. The resin's molten state during processing serves as a carrier that prevents direct interaction between particulates and orientation magnets, eliminating clumping
3Ease of manufacture
If thermosetting resin is used in MLC rotor manufacturing, then the composite structure can be formed, but the process is limited to smaller diameter rotors
Solution Approach 1:
The patent changes the resin system to thermoplastic, which has different processing parameters including higher melting point and different flow characteristics. This enables the manufacturing process to scale to larger rotor diameters while maintaining structural integrity and magnetic particulate distribution
Solution Approach 2:
The thermoplastic resin provides dynamic processing capabilities where the resin can be melted and flowed during manufacturing to accommodate larger rotor geometries, then solidifies to maintain the required structural properties. This dynamic behavior enables scalability to larger rotor sizes
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 reduces clumping and enhances magnetic alignment, resulting in a stronger magnetic pattern and more even distribution, preventing rotor imbalance and enabling the production of larger diameter rotors without the limitations of thermosetting resin processes.
Implementation Method 1
applying heat at said heating station to bond the tow and the tape so as to produce the magnetically loaded composite tape
Implementation Method 2
applying heat at said heating station to bond the tow and the tape
Implementation Method 3
the mandrel has a magnetic field (41,42) embedded therein to provide the anisotropic magnetic loaded pre-impregnated tape with a desired magnetic configuration
Implementation Method 4
feeding an anisotropic magnetically loaded pre-impregnated tape (8) to said heating station
Data Source
AI summary
A method of making a magnetically loaded pre-impregnated tape uses a drum 1 that is heated and which is associated with a heated bath 2 containing a thermoplastic resin solution. A fiber tape material 4 is fed onto the drum 1 and, just prior to the fiber tape material meeting the periphery of the drum, the fiber tape material 4 is impregnated with an isotropic magnetic particle material 6 to form a pre-impregnated tape 8. The pre-impregnated tape is fed to a heating station where it is bonded with a thermoplastic resin impregnated fiber tow to produce a magnetically loaded composite tape. The heating station includes a rotatably driven heated mandrel (20) having a magnetic field (41, 42) embedded therein to provide the pre-impregnated tape (8) with a desired magnetic configuration.