Resin-Molded Pump Rotor With Integrated Sealing and Impeller
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Solution Overview
Problem
Existing electric pump rotors require multiple resin molding steps, which hinder productivity improvements.
Innovation Solution
An electric pump rotor design that integrates a permanent magnet, rotor core, and adjacent member with a resin molded drive unit and blade portion in a single resin molding step, utilizing a closed surface portion, inner and outer extending portions, and first entire circumference protrusion portions to seal the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple resin molding steps are used to form the drive unit and blade portion separately, then the sealing and structural integrity are improved, but the productivity deteriorates due to increased manufacturing time
Solution Approach 1:
The patent combines the drive unit and blade portion into a single resin molded component that is formed in one molding step. The drive unit includes the housing, permanent magnet, and rotor core, while the blade portion is integrated as an impeller, eliminating the need for separate molding and assembly operations. This merging maintains sealing integrity through integrated design while significantly improving productivity.
Solution Approach 2:
The patent incorporates sealing structures directly into the resin molded portion during the molding process itself. The resin molded portion includes protrusions that engage with grooves on the rotor core and housing, creating sealed chambers that prevent fluid leakage. This preliminary formation of sealing features during molding eliminates the need for post-molding sealing operations.
2Manufacturing precision
If multiple resin molding steps are used to form separate components, then the manufacturing precision of each component is improved, but the device complexity increases
Solution Approach 1:
The patent integrates multiple functional components (housing, permanent magnet, rotor core, and impeller) into a single resin molded part. This consolidation reduces the number of manufacturing steps and assembly operations while maintaining the precision requirements for each functional element through integrated tooling and molding design.
Solution Approach 2:
The resin molded portion serves multiple functions simultaneously: it provides the structural housing, holds the permanent magnet and rotor core, forms the drive unit, and incorporates the blade portion as an integrated impeller. This multi-functionality reduces device complexity by eliminating the need for separate components and assembly operations.
3Productivity
If the drive unit and blade portion are integrally formed in a single resin molding step, then the productivity is improved, but the sealing reliability may deteriorate
Solution Approach 1:
While the drive unit and blade portion are formed in a single molding step, the resin molded portion is designed with internal segmentation into sealed chambers. The housing forms separate compartments for the permanent magnet and rotor core, with integrated sealing features that prevent fluid communication between chambers. This segmentation maintains sealing reliability through design rather than separate manufacturing steps.
Solution Approach 2:
The resin molded portion incorporates flexible sealing features such as protrusions and grooves that create interference fits and sealed interfaces. These flexible sealing elements accommodate manufacturing tolerances and thermal expansion while maintaining reliable sealing of the internal chambers, preventing fluid leakage despite the integrated construction.
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
Enhances productivity and reduces costs by allowing for a single resin molding process while effectively preventing fluid ingress into the drive unit.
Implementation Method 1
a first entire circumference protrusion portion that is formed over the entire circumference in the circumferential direction toward the one side in the axial direction at each of the inner extending portion and the outer extending portion, and is welded to the resin molded portion
Data Source
AI summary
An electric pump rotor includes: a permanent magnet; a cylindrical rotor core that holds the permanent magnet; an adjacent member that is provided adjacent to one side in an axial direction of the permanent magnet and the rotor core; and a resin molded portion in which a drive unit that covers the permanent magnet, the rotor core, and the adjacent member, and a blade portion that pressure-feeds a working fluid are integrally formed by resin molding.