Motor Core Production via Magnetic Phase Diffusion
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Solution Overview
Problem
The existing methods for producing motor cores with embedded permanent magnets have a limited degree of freedom in design due to the need for multiple molds and difficulty in inserting magnets with complex shapes into soft magnetic plate laminates.
Innovation Solution
A method involving the diffusion and penetration of rare earth elements into soft magnetic plates to form hard magnetic phases at specific positions, allowing for the creation of motor cores with varying shapes and designs without the need for multiple molds, using modifying members with lower melting points than the soft magnetic plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molded articles (permanent magnets) are used, then production is simplified, but the degree of freedom in shape is limited and multiple molds are required
Solution Approach 1:
The patent changes the physical state and composition parameters of the soft magnetic plate by introducing modifying members containing rare earth elements. Through heat treatment, the modifying members diffuse into the soft magnetic plate to form hard magnetic phases, transforming the material properties directly within the plate rather than using separate molded magnets. This enables complex shapes without requiring multiple molds.
Solution Approach 2:
The patent merges the functions of the soft magnetic plate and the permanent magnet into a single integrated structure. The modifying members are brought into contact with the soft magnetic plate, and through diffusion and heat treatment, the hard magnetic phase is formed within the soft magnetic plate itself, combining what were previously separate components into one unified motor core structure.
2Adaptability or versatility
If multiple types of permanent magnets are prepared, then various motor core types are supported, but the number of molds required increases
Solution Approach 1:
The patent creates a universal producing method that can generate various types of motor cores using a single basic process. By controlling the position, amount, and composition of the modifying members, and adjusting heat treatment parameters, the same diffusion-based method can produce different hard magnetic phase patterns suitable for various motor core types, eliminating the need for multiple specialized molds.
Solution Approach 2:
The patent applies local quality by allowing different regions of the soft magnetic plate to have different magnetic properties through selective placement of modifying members. The modifying members can be positioned at specific locations and in specific amounts to create localized hard magnetic phases with different characteristics, enabling diverse motor core designs within a single unified production approach.
3Ease of manufacture
If through-holes are punched to form cavity parts, then permanent magnets can be embedded, but punching molds are required and the process becomes complex
Solution Approach 1:
The patent replaces the mechanical punching process with a thermal diffusion process. Instead of using punching molds to create physical cavities, the modifying members are brought into contact with the soft magnetic plate and heat-treated to diffuse rare earth elements into the plate, forming hard magnetic phases in the desired locations. This substitutes mechanical cavity formation with a thermal-chemical process that directly creates the magnetic structure.
4Adaptability or versatility
If complex shaped permanent magnets are used, then design freedom is increased, but insertion into the laminate becomes difficult
Solution Approach 1:
The patent performs preliminary action by forming the hard magnetic phases directly within the soft magnetic plate during the heat treatment process, before any assembly operations. The modifying members are placed on the soft magnetic plate surface, and through diffusion and heat treatment, the complex magnetic structures are created in situ within the plate itself, eliminating the need for subsequent insertion operations.
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 enables the production of motor cores with a high degree of design freedom, allowing for complex shapes and reduced production costs by eliminating the need for multiple molds and simplifying the insertion of magnets, while maintaining effective magnetic properties.
Implementation Method 1
causing each modifying member to diffuse and penetrate into the soft magnetic plate from a contact surface between the soft magnetic plate and the modifying member
Implementation Method 2
preparing modifying members containing an alloy having a melting point lower than a melting point of the soft magnetic plate
Data Source
Figure 1A~2B
Figure 2C~3A
Figure 3B~3D
AI summary
A method of producing a motor core (30) includes preparing soft magnetic plates (11) containing a transition metal element, preparing a modifying member (21) containing an alloy having a melting point lower than a melting point of the soft magnetic plate (11), bringing the modifying member (21) into contact with part of a plate surface of the soft magnetic plate (11), causing the modifying member to diffuse and penetrate into the soft magnetic plate (11) from a contact surface between the soft magnetic plate (11) and the modifying member (21) and forming a hard magnetic phase-containing part (16) in part of the soft magnetic plate (11), and laminating a plurality of soft magnetic plates (11) on each other after the modifying member (21) is brought into contact with part of the plate surface of the soft magnetic plates (11).