Motor Core Magnet Fixing with Two-Stage Resin Curing
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Solution Overview
Problem
Existing methods for fixing permanent magnets in motor cores using thermoplastic or thermosetting resin materials face inefficiencies due to high injection pressures, potential deformation of the motor core, and unnecessary curing of resin in the injection device, leading to low production efficiency and accuracy issues.
Innovation Solution
A manufacturing method involving a synthetic resin material that remains softened at a first temperature and cures at a higher second temperature, allowing for low-pressure injection and subsequent curing in a separate heating furnace, enabling the injection device to be released immediately after filling, thus improving production efficiency and avoiding resin overflow and curing in the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermoplastic resin material is injected at high pressure to fill the magnet accommodating portion, then the resin can be injected quickly, but the injection device cannot be retracted until curing is complete, reducing production efficiency
Solution Approach 1:
The process is divided into two independent stages: injection stage (at first temperature) and curing stage (at second temperature). The injection device completes injection and can be retracted immediately, while curing occurs separately in the heating furnace, eliminating the occupation time conflict.
Solution Approach 2:
The heating furnace acts as an intermediary device that takes over the curing function after injection. The injection device transfers the resin-filled magnet accommodating portion to the heating furnace, which then completes the curing process without requiring the injection device to remain occupied.
2Productivity
If high injection pressure is used to fill the magnet accommodating portion, then the resin material can be injected quickly, but the peripheral edge portion of the stacked body may deform
Solution Approach 1:
The resin material's temperature is changed to a first temperature that provides optimal viscosity for low-pressure injection. This parameter change allows the resin to flow and fill the magnet accommodating portion effectively without requiring high injection pressure, thereby preventing deformation of the peripheral edge portion.
3Reliability
If thermosetting resin material is used in larger amount to ensure filling, then the magnet accommodating portion can be completely filled, but the excess resin overflows and cures in the injection device, requiring removal
Solution Approach 1:
The resin material is preheated to the first temperature before injection to achieve optimal flow properties. This preliminary heating action ensures the resin can be injected at low pressure and fills the magnet accommodating portion completely without requiring excess material, preventing overflow and subsequent curing in the injection device.
4Strength
If the injection device remains connected during curing, then pressure can be maintained, but the injection device is occupied and production efficiency is reduced
Solution Approach 1:
The process is segmented into injection phase and curing phase. During injection, the resin is filled at the first temperature. During curing, the stacked body is transferred to a heating furnace that maintains the second temperature, providing the necessary fixing strength without requiring the injection device to remain connected.
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 method enhances production efficiency by allowing for immediate release of the injection device after filling, reducing the need for high pressure and preventing resin curing in the device, while ensuring sufficient fixing strength and accuracy of the motor core.
Implementation Method 1
a synthetic resin material that is in a softened state at a first temperature and is cured at a second temperature that is higher than the first temperature
Implementation Method 2
the synthetic resin material that is in a softened state at a first temperature and is cured at a second temperature that is higher than the first temperature
Data Source
AI summary
A manufacturing method for a motor core in which a magnet is fixed in a magnet accommodating portion using synthetic resin material includes: a fixing step of fixing the a permanent magnet in the a magnet accommodating portion using a synthetic resin material, wherein the fixing step includes: an injection step of setting a temperature of the synthetic resin material to a first temperature and injecting, with an injection device having a container capable of maintaining the synthetic resin material in the softened state, the softened synthetic resin material into the magnet accommodating portion; and a curing step of raising the temperature of the synthetic resin material injected into the stacked body to a second temperature to cure the synthetic resin material, with the injection device being moved away from the stacked body.