Resin-impregnated Laminate Pole-piece for Magnetic Gear
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Solution Overview
Problem
Conventional magnetic gear pole-piece structures often require additional components like metal frames or housings for mounting, which can compromise magnetic permeability and efficiency due to air gaps and mechanical contact.
Innovation Solution
A pole-piece structure composed of laminate plates held together by a solid, non-magnetic resin material, such as silica-filled epoxy resin, that fills channels formed between the plates, eliminating air gaps and mechanical attachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metal frames or housings are used to mount the pole-piece, then structural support is provided, but magnetic permeability and efficiency deteriorate due to air gaps and mechanical contact
Solution Approach 1:
The patent replaces the conventional mechanical mounting system (metal frames, housings, and fasteners) with a resin-impregnated laminate structure. The resin saturates the laminate plates and fills all interstitial spaces, creating a monolithic structure that eliminates the need for separate mechanical mounting components. This substitution removes air gaps and metallic contact points that would otherwise disrupt magnetic flux paths, thereby maintaining magnetic efficiency while providing structural support.
Solution Approach 2:
The patent employs a composite structure consisting of laminate plates (providing structural framework) impregnated with resin (providing binding and filling). This composite material combines the mechanical strength of the laminate with the gap-filling, non-magnetic properties of the resin. The resulting composite pole-piece maintains structural integrity while minimizing interference with magnetic flux, as the resin-saturated structure eliminates air gaps without requiring metallic fasteners or frames.
2Stability of the object's composition
If additional mounting components are used to hold the pole-piece, then structural stability is improved, but device complexity increases
Solution Approach 1:
The patent merges the structural support function and the pole-piece body into a single integrated component. The laminate plates are stacked and resin-impregnated to form a unified monolithic structure where the mounting functionality is inherent to the pole-piece itself rather than being provided by separate components. This merging eliminates the need for additional mounting parts while maintaining structural stability.
Solution Approach 2:
The pole-piece structure is designed to be self-supporting through the resin-impregnated laminate construction. The resin saturates the laminate and fills all voids, creating a self-binding structure that requires no external fasteners, frames, or housings for mounting. The structure serves its own mounting needs through its intrinsic resin-filled design, eliminating the requirement for separate mounting components.
3Loss of energy
If solid non-magnetic material is used to hold laminate plates together, then magnetic permeability is improved by eliminating air gaps, but manufacturing complexity increases
Solution Approach 1:
The patent employs a liquid resin that is applied to the stacked laminate plates and then cured to form a solid binding matrix. The liquid state of the resin during application allows it to flow into and fill all channels, apertures, and interstitial spaces between the laminate plates. After curing, the resin becomes a solid non-magnetic material that permanently fills these spaces, eliminating air gaps and improving magnetic permeability. This liquid-to-solid phase transition simplifies the manufacturing process compared to attempting to mechanically fill gaps with solid materials.
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 configuration enhances magnetic permeability and reduces mechanical contact, improving the efficiency and performance of magnetic gears by maintaining a frictionless torque transfer without the need for additional mounting components.
Implementation Method 1
a solid, substantially non-magnetic material is provided throughout each channel to hold the plurality of laminate plates together
Implementation Method 2
The use of a solid, non-magnetic material to hold the plates together has been found to provide an improved structure as compared to conventional devices, which typically involve the use of further components such as a metal frame or housing located around the pole-piece to hold the pole-piece in position
Data Source
AI summary
The disclosure provides a pole-piece structure for a magnetic gear, comprising a plurality of laminate plates, wherein each plate comprises one or more apertures and an aperture in each plate aligns with an aperture in an adjacent plate to form one or more channels extending from a first end of the laminate plates to a second, opposite end of the laminate plates, wherein a resin cast is provided within each channel to hold the plurality of laminate plates together.