Resin Filling Device Diameter Reducing Part Flash Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing resin filling devices for electric motor rotors often result in flash formation during the curing process, leading to inefficiencies and increased costs due to the need for dedicated equipment or manual flash removal, and unreliable control over the separation of cured resin, which can cause damage or malfunction in electric motors.
Innovation Solution
A resin filling device with a resin feeding mold and opposing mold that applies compression, featuring discharge outlets with a diameter reducing part to control the separation of cured resin, preventing flash formation by concentrating stress at the smallest diameter portion, thus ensuring a smooth break and reducing the need for flash removal processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin filling device is used to fill magnet insertion holes with molten resin, then the magnets are fixed in the laminated iron core, but residual resin remains on the laminated iron core side forming flash
Solution Approach 1:
A dummy plate is introduced as an intermediary component between the resin filling device and the laminated iron core. The dummy plate includes discharge outlets that receive the molten resin, allowing the resin to be filled into the magnet insertion holes while the dummy plate captures and contains the residual resin, preventing it from forming flash on the laminated iron core.
Solution Approach 2:
The discharge outlet structure is segmented into multiple functional parts including a dummy plate portion and a gate plate portion. The dummy plate portion is separated from the gate plate portion, allowing the residual resin to be contained in the dummy plate while the gate plate maintains the filling function. This segmentation enables the resin to be divided into useful filled resin and residual resin that can be separately managed.
2Ease of manufacture
If a dummy plate is provided between the upper mold and laminated iron core to remove residual resin, then some residual resin is removed, but control over split positions of cured resin is not possible and flash may still form
Solution Approach 1:
The discharge outlet is designed with non-uniform cross-sectional area along its length, creating a diameter reducing part where the inner diameter gradually decreases. This local variation in geometry concentrates stress at the smallest diameter portion, ensuring that the cured resin consistently breaks at this specific location rather than at random positions, thereby reliably preventing flash formation.
Solution Approach 2:
The cross-sectional parameters of the discharge outlet are changed along its length, with the inner diameter gradually reducing from the resin filling side toward the laminated iron core side. This parameter change creates a controlled stress distribution that determines the break position of the cured resin, ensuring it occurs at the diameter reducing part rather than forming flash on the laminated iron core.
3Object-generated harmful factors
If flash removal process is added to the production line to remove flash, then flash is removed from the laminated iron core, but production efficiency is reduced and equipment cost and labor cost are increased
Solution Approach 1:
The invention converts the potentially harmful residual resin that would form flash into a beneficial contained element. By designing the discharge outlet with a diameter reducing part, the residual resin is intentionally allowed to remain but is confined to the dummy plate portion, where it serves as a natural separator that prevents flash formation without requiring additional removal processes.
Solution Approach 2:
The discharge outlet structure itself provides the flash prevention function through its geometric design. The diameter reducing part automatically controls the break position of cured resin and contains residual resin within the dummy plate, eliminating the need for external flash removal equipment or manual operations. The system serves its own flash prevention needs through its inherent structure.
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 solution effectively prevents flash formation, enhancing production efficiency and reducing equipment and labor costs by ensuring reliable resin separation and smooth end faces on the laminated iron core, allowing for continuous operation without additional flash removal steps.
Implementation Method 1
it is possible to break and separate the cured resin by concentrating a stress to a portion of a distal end of the diameter reducing part where the diameter is the smallest
Implementation Method 2
a pressing mechanism part that applies a compression force in a state where the laminated iron core is sandwiched between the resin feeding mold and the opposing mold
Data Source
AI summary
A resin filling device for a laminated iron core, the resin filling device being used when a magnet insertion hole provided in the laminated iron core of a rotor for an electric motor is filled with a molten resin for fixing a magnet. The resin filing device configured with a resin feeding mold, an opposing mold, and a pressing mechanism that applies a compression force with the laminated iron core sandwiched between the resin feeding mold and the opposing mold. The resin feeding mold includes one or more discharge outlets arranged so as to face the opening of the magnet insertion hole, and configured to include a diameter reducing part in which an inner diameter is reduced gradually along a discharge direction of the molten resin. A diameter reducing part is arranged inside of the laminated iron core.