Powder Magnetic Core Ejection Using Spring-Back Powder Layers
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Solution Overview
Problem
The existing method for manufacturing powder magnetic cores results in increased iron loss due to the breaking of insulating coating films during the pressing process, caused by plastic flow between the pressed powder and the die.
Innovation Solution
A method involving the formation of a soft magnetic powder layer surrounded by a different powder layer with a higher spring back rate, which reduces friction and prevents coating film breakage and cracking when the pressed powder is removed from the die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pressed powder is removed from the die by sliding, then the manufacturing process can be completed, but the insulating coating film on the soft magnetic powder breaks due to rubbing, increasing iron loss
Solution Approach 1:
A release agent layer is introduced as an intermediary substance between the pressed powder and the die wall. This release agent prevents direct contact and rubbing between the pressed powder surface and the die, thereby protecting the insulating coating film from breaking during the ejection process while still allowing the manufacturing process to be completed
2Productivity
If the pressed powder is removed from the die by sliding, then the manufacturing process can be completed, but plastic flow occurs in the soft magnetic powder, causing formability issues
Solution Approach 1:
The release agent acts as a mediator that reduces friction and plastic flow during ejection. By preventing direct rubbing between the pressed powder and die wall, the release agent maintains the structural integrity and dimensional accuracy of the pressed powder, thereby improving formability while enabling process completion
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 effectively reduces iron loss and enhances the formability of the powder magnetic core by minimizing friction and preventing coating film damage during the pressing process.
Implementation Method 1
a different powder layer having a spring back rate higher than that of the soft magnetic powder layer by 0.6-1.1% is formed on upper and lower sides of the soft magnetic powder layer
Data Source
AI summary
A method for manufacturing a powder magnetic core, the method including: forming a soft magnetic powder (SMP) layer by putting an SMP having a surface on which an insulating coating film is formed into a space surrounded by a lower punch and a die; forming a pressed powder by compressing the SMP layer in the die by the lower punch and an upper punch; and causing the pressed powder and the die to slide relative to each other and then removing the pressed powder from the die is provided. In forming the SMP layer, a different powder different from the SMP is put into the space before and after the SMP is put into the space and a different powder layer having a spring back rate higher than that of the SMP layer by 0.6-1.1% is formed on upper and lower sides of the SMP layer.