Rotor Member Interface Structure for Stronger Magnet Bonding
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Solution Overview
Problem
There is a need to improve the adhesion strength between the soft magnetic yoke section and the magnet section in conventional rotor members used in rotary electric machines, as existing technologies do not effectively enhance this fixing strength.
Innovation Solution
A rotor member design featuring a soft magnetic body and a hard magnetic body with a contact surface that protrudes radially, where the pressure for forming the hard magnetic body is higher than for the soft magnetic body, allowing for increased contact area and adhesion, and a manufacturing method involving compression-molding of mixed powders to align and integrate these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional compression molding is used for both soft magnetic powder and hard magnetic powder, then manufacturing simplicity is maintained, but adhesion strength between soft magnetic body and hard magnetic body is insufficient
Solution Approach 1:
The patent applies different compression pressures to the soft magnetic powder and hard magnetic powder during molding. Specifically, the hard magnetic powder is compressed at a higher pressure than the soft magnetic powder, creating stronger adhesion at the contact surface between the two magnetic bodies without requiring additional complex manufacturing steps
Solution Approach 2:
The patent creates a localized high-pressure zone at the contact surface between the soft magnetic body and hard magnetic body. By applying higher compression pressure specifically to the hard magnetic powder layer, the adhesion strength is enhanced at the critical interface region while maintaining standard molding conditions for the bulk materials
2Strength
If a flat contact surface is used between soft magnetic body and hard magnetic body, then manufacturing simplicity is maintained, but fixing strength is insufficient
Solution Approach 1:
The patent designs the contact surface between the soft magnetic body and hard magnetic body with a protruding shape that extends in the radial direction. This curved or protruding contact surface increases the contact area and improves fixing strength compared to a flat contact surface, while still being formable through compression molding
3Reliability
If more soft magnetic bodies are used, then magnetic characteristics are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent creates a composite magnetic body structure by combining soft magnetic powder and hard magnetic powder in a single molded component. The hard magnetic body provides strong magnetic properties while the soft magnetic body provides good magnetic conductivity, achieving superior overall magnetic characteristics without requiring multiple separate components
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
The solution significantly improves the shear strength and fixing strength between the soft and hard magnetic bodies, enhancing the magnetic characteristics and mechanical stability of the rotor member, while allowing for fewer soft magnetic bodies to achieve desired magnetic performance.
Implementation Method 1
compression-molding soft magnetic powder and the preliminary hard magnetic body from a first direction
Data Source
AI summary
A rotor member that includes: a soft magnetic body; and a hard magnetic body that is in contact with a peripheral surface of the soft magnetic body in a radial direction centered on the central axis, wherein a contact surface between the soft magnetic body and the hard magnetic body has a shape protruding in the radial direction entirely around the central axis such that a position of a minimum width of a portion forming the contact surface in the soft magnetic body in the radial direction is different from positions of a first end surface and a second end surface of the soft magnetic body, and positions of a third end surface and a fourth end surface of the hard magnetic body.